CPT International 02/2019

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SPECIAL: GIFA 2019 DISA Premieres of game-changing foundry innovations for Zero Defect Manufacturing At GIFA 2019, DISA, Taastrup, Denmark, will reveal three radical new digitally-driven innovations that move foundries closer to Zero Defect Manufacturing (ZDM). Inspired by DISA’s unmatched experience in helping customers continuously improve casting quality, these cutting-edge ZDM solutions – the novel Trace and Guidance (TAG) concept, the patent-pending Mold Accuracy Controller (MAC) and the upgraded Monitizer – open the door to a new era of scrap elimination. Visitors to the DISA section of the Norican Group stand will have hands-on access to both hardware and digital models so they can see for themselves how process data, real-time analysis and forensic quality control combine to help trace and eliminate scrap. “Finding the root cause of scrap can be extremely difficult,” says Per Larsen, Portfolio and Innovation Manager at DISA. “The total quality-related costs across foundries and casting users can represent up to 10 % of the casting price.” For the first time ever, foundries can gain full traceability with DISA’s ingenious new Trace and Guidance (TAG) concept. TAG adds a unique ID number to each casting to provide the missing link between individual scrapped castings and their process parameters like sand compressibility, shot pressure and pouring temperature. TAG tracking also paves the way for advanced machine-learning-based analysis of scrap causes. “TAG tracking promises to be a major game changer for our industry, helping drive down quality-related costs to previously unseen levels,” says Larsen. “GIFA visitors will be able to explore the patent-pending TAG design for themselves in the demonstration area on our stand and sign up for exclusive news as this exciting concept is developed further.” The trailblazing Mold Accuracy Controller (MAC) forms the second plank of DISA’s ZDM strategy. The MAC alerts operators to mold mismatches and gaps – causing scrap, rework and damaging melt run-through – before the mold is DISA CIM (Computer Integrated Modules), featuring a completely new suite of data analysis and alerting tools poured. At GIFA 2019, visitors to the DISA stand can test drive the MAC using a Disamatic Digital Twin (a digital simulation of a molding machine). They can change the virtual machine’s settings via a Disamatic D3 control panel and immediately see how those changes affect mold quality. “Delegates can inspect a full-size MAC on the stand, then use the Digital Twin to virtually test how the MAC monitors the molding machine’s output and helps spot any developing problems,” explains Larsen. “They will get a real feel for how operators are kept fully informed and can react to quality issues seconds after they first appear and, most importantly, before pouring the molds.” The MAC will be released at GIFA as a retrofit option for Disamatic machines with Automatic Mold Conveyors, helping more customers wave goodbye to scrap. GIFA also sees the release of Monitizer | CIM, DISA’s third ZDM solution. This is the next generation of DISA CIM (Computer Integrated Modules), featuring a completely new suite of data analysis and alerting tools. As the digital platform which collects and shares data between your foundry equipment, Monitizer keeps processes synchronized and delivers a full digital view of real-time and historic foundry data. Monitizer | CLOUD from Norican Group extends the platform, using IIoT technology to collect, monitor, and analyse complete foundry data from one or multiple global foundry sites. “With the Disamatic Digital Twin, MAC, TAG, and Monitizer, visitors can see how DISA’s disruptive digital innovations make it possible to “dive into the data” to troubleshoot problems, optimize critical foundry processes and take major steps towards zero scrap,” states Larsen. During on-stand sessions and within the official GIFA lecture programme, DISA experts will discuss how its ZDM solutions enable the data-driven foundry and help improve productivity, quality and resource utilization. Hall 11, stand A74-A78 www.disagroup.com Photo: Disa 56
FOSECO Filtration for iron and steel foundries The demand for improved casting integrity and performance continues, often associated with the need to reduce casting weight. The benefits provided by molten metal filters are increasingly valuable to casting producers and their customers in achieving these goals. In addition to enhancements to the range of Sedex and Stelex filters that offer foundries enhanced choice and performance characteristics in filter application, Foseco will be launching a new filter technology for large, high value steel castings. The Hollotex shroud filtration system combines the known benefits of Stelex filters with a fused silica shroud. This innovative technology provides a method of protecting the molten steel as it is poured from a bottom pour ladle into the mould and casting cavity. Aspiration of air is eliminated reducing re-oxidation inclusions and enhancing the performance of the integral filters. An application case study will detail the major improvements that this process can facilitate in the production and quality of highly specified castings. Recent developments in the Sedex and Stelex product portfolios offer foundries increasing choice in filter products. The attributes of these products will be compared so the user can understand the associated benefits and select the correct filter type for their casting needs. Foseco will be showing many case studies demonstrating the benefits provided by applying Sedex and Stelex filters to a variety of iron and steel castings. These will be complemented by Magmasoft simulations which model the molten metal flow control and turbulence reduction that are vital to achieving high finished casting quality. Hall 12 – Stand A1 + A2 www.foseco.com Photo: Foseco Hollotex shrould application for large steel castings will be highlighted at the Foseco stand at GIFA 2019 CASTING PLANT & TECHNOLOGY 2/2019 57
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EDITORIAL It’s Showtime! The quad
Page 5 and 6: CONTENTS CLEANING, FETT LING & FINI
Page 7 and 8: “Innovations are crucial for succ
Page 9 and 10: YXLON - QUALITY ASSURANCE AND PROCE
Page 11 and 12: the first cores would take place as
Page 13 and 14: After removal, a robot deburrs the
Page 15 and 16: FOUNDRY - A PASSION FROM OUR HEART.
Page 17 and 18: Photos: Klaus Vollrath carried out
Page 19 and 20: Left: Fully automatic plant for hea
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Page 23 and 24: Potential solutions in foundry plan
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Page 29 and 30: State of the art Exothermic feeder
Page 31 and 32: Figure 6: GTP Schäfer feeder datab
Page 33 and 34: CASTING Special GIFA 2019 Part 2: O
Page 35 and 36: “Germany is a trade fair country
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Page 41 and 42: HÜTTENTAG 2019 Get-Together of the
Page 43 and 44: The Bright World of Metals With the
Page 45 and 46: FOSECO Non ferrous melt shop Insura
Page 47 and 48: IMERYS Kersand and Durandal - the r
Page 49 and 50: dehyde potential. Furthermore, the
Page 51 and 52: BÜRKERT Modular platform for heati
Page 53 and 54: Photo: Foseco Foseco’s new, paten
Page 55: IDECO Hydrogen Analysis in Aluminum
Page 59 and 60: WHEELABRATOR A new wheel, advanced
Page 61 and 62: GIFA 2019 hall 16 / C11 Torque moto
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Page 65 and 66: MASTER EVERY MELT Speed up the prod
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Page 69 and 70: The Kinetic Assembly Structure refl
Page 71 and 72: Production of a 3-D pattern and its
Page 73 and 74: Order Form - NEWSLETTER 2019 NEWSLE
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CPT International 02/2019

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