Established by foundry technology experts DISA, the test facility will run production trials for new and existing castings to physically prove the green sand process meets both casting specifications and cost expectations. The test facility will also aid foundries producing iron castings.
DISA president Ulla Hartvig Tønnesen, wants to make it easier for casting producers to unlock the potential of green sand for their castings, instead of using more costly methods like die casting or no-bake – and cut costs by up to 20%.
“We want to challenge the industry mindset that certain castings must be made with certain technologies,” says Ulla. “DISA invented high-efficiency, high-quality vertical moulding and perfected it for 60 years. We’re seeing more foundries investigate green sand for aluminum, steel, brass and bronze applications, and this facility will give them the confidence to move ahead with production in green sand.”
Up to 20% cost reductions
“We typically see a 15% lower cost per casting by switching to green sand, but it can be 20% or more,” says Ulla. “It’s a big opportunity for non-iron foundries currently using processes like shell, no bake and die casting.”
The test foundry conducts intensive, end-to-end process development using its complete green sand line. That includes melting, sand mixing, vertical moulding and core shooting, plus metal chemistry analysis and MAGMASOFT simulation for gating and feeding design. Foundries can also submit sand samples to test Simpson sand reclamation and find out what percentage can be reused.
“It’s hard to make a breakthrough on your own,” says DISA’s innovation manager, Per Larsen. “Partner with us if you have a non-iron casting you would like to produce in green sand – we’re here to help.”
Green sand gives you an edge
Currently working with steel castings, the test foundry will focus on a different alloy every few months, with regular updates via the DISA LinkedIn channel. The facility has already proved to one major US foundry that a DISAMATIC D3 vertical moulding line is perfect for its brass castings.
Ultra-flexible machines like the DISA MATCH and DISAMATIC are already widely used in short-run aluminum, brass and bronze applications.
“In a highly competitive global market, moving to green sand for non-iron parts gives foundries the edge they need,” says Ulla. “We – and the DISA test foundry – are here to make it happen.”
About DISA
DISA, a Norican Group technology, develops and manufactures a complete range of metal casting production solutions for the ferrous and non-ferrous foundry industries. Headquartered in Taastrup, Denmark, with a North American facility based in LaGrange Georgia, DISA is the world-leading supplier of complete foundry solutions and services, as well as state-of-the-art green sand moulding equipment.
DISA also offers its class-leading Monitizer digital solutions that support the whole digital journey from data collection to AI-driven casting quality optimization. Monitizer works in all types of foundries and processes, and with any vendor equipment, to deliver serious process improvements – fast.
