×
The platform for the Entire Casting Industry
This requires die casting cells with a clamping force greater than 6,000 tons.
The approach of substituting as many individual parts and processes as possible with large castings and thus even reducing costs, weight and CO2 factors while simplifying the production process sounds tempting. On the other hand, there are high upfront investments in new systems and infrastructure, the reconfiguration of product lines and technical challenges related to the production and further use of the large parts.
During a background discussion with Klaus Sammer and Dr. Thomas Kopp at BMW's light metal foundry in Landshut, we were able to discuss the main arguments for and against large castings and gain insight into BMW`s specific point of view.
"There is no "right" or "wrong" answer to the giga/megacasting question
Kopp and Sammer are sought-after discussion partners at congresses and symposiums, as they have dealt intensively with the issues surrounding the production of large castings and are well aware of the advantages and disadvantages.
What is the situation at the BMW light metal foundry in Landshut, Germany in 2024?
The BMW Group light metal foundry in Landshut is a highly innovative location known for a wide and unique range of casting technologies. These include both conventional gravity and low-pressure die casting.
A notable technique ist the injector casting process, developed and patented by the casting specialists in Landshut in 2007. It combines the advantages of gravity and low-pressure die casting.
The process involves filling the cavity using an injector at the mold's base and moving it upwards during the casting. This ensures the outlet opening remains below the molten bath's surface throughout the filling process, leading to a layered mold filling beneficial for the solidification process. This method allows for the production of highly complex and functional components, such as the central housing of electric motors. The sand cores needed for creating undercuts are exclusively made with inorganic binder systems, resulting in virtually emission-free casting—a practice in place for over 15 years, as emphasized by Kopp and Sammer.
The collaboration has already begun its first joint project, with pour-tech AB supporting Wesman with insights from over 500 installed systems. The aim of the cooperation is the independent distribution, project planning, manufacturing installation at customer sites, and subsequent service of AI-assisted 3D line laser-controlled, unheated pouring equipment by Wesman for the Indian market. The partnership seeks to unlock the great potential of the Indian foundry industry, enabling the utilization of existing and newly established high-performance molding facilities and core package lines through an appropriate pouring process with increased yield. The pouring process should no longer limit the installed capacities of molding facilities.
During the IFEX 2024 in Bangaluru there was the first joint presentation, which was characterized by a very high encouragement from the Indian foundries.
Die casting solutions for non-removable hollow channels in the component
The focus is on the production of component cavities using the aluminium die casting process. Using gas injection technology, complex structures and internal channels can be created during the casting process without the need for additional machining steps. Images 1 and 2
Renewable energies and green hydrogen are currently being discussed as the best way to achieve these ambitious targets. However, the capacities of renewable energies in many parts of the world, Europe and also in Germany are currently not large enough to produce sufficient quantities of green hydrogen using the electrolysis process. Natural hydrogen deposits are rare on our planet and do not offer any guarantee of supply. The Climate Action Plan 2050 [1] contains targets that describe the reduction of greenhouse gas emissions by 2030 (Table 1). According to this, approx. 50% of greenhouse gas emissions (in CO2 eq.) are to be reduced in industry.
"Although the grinding market has an advantage in that it offers numerous niches in which specialized medium-sized companies can work successfully, the pressure for change calls for continuous re-evaluation: How is the market changing? How do I react as a company?"
Tesch therefore focused on automation and documentation of empirical knowledge at an early stage in order to prevent a shortage of skilled workers. In the case of supply chains it was necessary to counteract the dependence on China. A strategic decision was therefore taken in Ludwigsburg to purchase 20 per cent of super hard materials from regions other than China despite much higher costs. Tesch has a high production depth and produces solely in Germany. Raw materials have to be imported.
New materials as innovation drivers
According to the Managing Director, the biggest technological challenges primarily involve the handling of new materials for which grinding solutions have to be found at ever shorter time intervals:
"At times, we have to deal with a very large number of material compounds," he said.
This development is also a topic for Prof. Karpuschewski at the IWT in Bremen. "Processing of new materials and material compounds has long been known to us from geometrically defined cutting and precision machining of optical materials," he stated.
"From a scientific viewpoint, we are actively addressing these questions and working on a large number of technological solutions. The key factor is the evaluation of process influences on component quality in different materials for which extensive physical analysis is carried out in Bremen.
More time and effort for imparting process know-how
An interdisciplinary research team is working on tool development at Tesch. Tools often have to be adapted individually to customers' requirements. The process support costs are also increasing.
"There is an ever increasing need to impart know-how to users in order to ensure high-quality and reproducible grinding processes," emphasized Georg Gerlitzky.
This always depends on highly qualified personnel with many years of experience.
Cooperation with scientific institutes has a long tradition at Tesch. By its own account, the company collaborates with different institutes, is active in various working parties and values exchanges. This also includes participation in research projects. The company is currently working with Berlin Technical University on a project involving the production of metallic grinding tools with the aid of additive manufacturing.
Know-how transfer through research projects
The grinding experts in the Institute of Machining Technology (ISF) at Dortmund Technical University are also convinced about the positive prospects for additive manufacturing. Dr. Monika Kipp, Head of the Grinding Technology Department, stated in this respect that additive manufacturing is now being used in the grinding technology industry and is opening up new prospects.
A number of research projects involving new production processes and alternative tool concepts are currently being conducted at the ISF. According to Dr. Kipp, the highlights include basic studies on the use of diamond-coated foam materials for precision surface treatment which enable purposeful processing of filigree structures. Two other projects confirm the growing importance of diamond and cBN. For example, one group is involved in the identification of microscopic wearing mechanisms of diamond and cBN in precision grinding of hardened steel. In another project studies are being carried out on cold gas spraying for the manufacture of cBN metal composite layers and their qualification for use as a grinding tool. This also comes within the context of additive manufacturing.
Monika Kipp sees a great opportunity in the close cooperation between science and industry. She said that, thanks to the constant exchanges, both science and companies obtain suggestions for new topics and research projects. On the other hand, the institutes could provide support through basic research or generate substantial value-added through references to related research results. The ISF has cooperation partnerships with both larger enterprises and smaller companies.
Exploit potential in the area of sustainability
Just like other areas of industrial production, the topic of sustainability is also affecting grinding technology. Karpuschewski primarily sees two starting points for the grinding process: "In Bremen we have been preoccupied for many years with need-based use of cooling lubricants during grinding since this still harbors enormous saving potential. Thanks to adapted feed and a nozzle design, energy consumption can be drastically reduced while still maintaining the same component quality. This has a direct effect on the sustainability of the process. In the light of rapidly increasing energy costs, new promising approaches could also open up when recycling grinding waste.
According to Managing Director Gerlitzky, Diamant-Gesellschaft Tesch has long been committed to energy-saving and resource-conserving production although tool manufacturers are rather limited in the ways they can influence its use at their customers. At Tesch, for example, the primary energy source - electricity - has been changed completely to green electricity from hydroelectric power plants. This was made possible through cooperation with a local partner.
"The topic of sustainability should be part of the DNA of every medium-sized company," emphasized Gerlitzky. "We must position our company here in a progressive way as only then can we secure advantages in the long term."
How stable is the process?
Together with the experts from ALUWAG, let's do the practical test and see how stable the process is and how the advantages can be summarised. Together with the project partners TIK, MAGIT, Surtechno and HS Aalen, the Swiss die casters were able to overcome many hurdles in advance. It is now possible to simulate the gas injection process with Flow 3D in terms of filling and solidification as well as the complete flow of the melt.
The quality characteristics for the component are determined together with the customer and defined in terms of cross-section, wall thickness distribution, residual dirt, tightness and bore.
The injection process at the die casting cell runs smoothly with experienced employees at the gas injection unit with expert operation of the gate valve to inject the nitrogen.
The targeted injection of gas into the melt during the casting process creates cavities that reduce the weight of the components and at the same time improve their strength. It enables more efficient and cost-effective production of high-quality components with complex geometries. Optimised material properties, higher mould filling and a reduction in distortion and porosity are further advantages of the process.
The result is high-quality aluminium die-cast parts with cavities and/or internal channels.
The advantages are obvious, especially for components in power electronics, but also for media-carrying components or when it comes to targeted weight reduction, because the part produced with gas injection usually replaces an entire assembly and saves on tools or additional welding processes.
Together with its research partners, ALUWAG has worked intensively on this topic and can now use its practical experience and accumulated expertise to establish that series production using gas injection processes is a serious possibility. Compared to other processes, the potential savings in tools, materials and machining costs open up enormous advantages that lead to optimal solutions for the right components.
About ALUWAG:
ALUWAG supplies customised die-cast components and even entire assemblies to global brands from various industries. The company responds to individual customer requirements that go far beyond the usual standards.
Experience, expertise and passion form the basis for innovative die-casting solutions.
ALUWAG has an integrated quality management system and is certified to the following standards:
- ISO 9001
- IATF 16949
- ISO 14001 / 45001
The following machines with different clamping forces in tonnes are used at the Niederbüren site:
400, 530, 800, 1'200, 1'800, 2'200
In addition to conventional core shooting, sand cores can also be produced at the Landshut site using additive core printing with inorganic binder systems. This ensures the future viability of the site.
In the area of die casting, the facility operates ten systems with clamping forces ranging from 3,000 to 6,000 tons. Strong arguments exist for using die casting cells with clamping forces over 6,000 tons, potentially up to 16,000 tons, as the decision heavily depends on the specific production process requirements, site conditions (e.g., material flow/logistics), and company standards and objectives.
The substitution of sheet metal components with cast components can eliminate numerous manufacturing and assembly steps. For instance, the suspension strut support replaces about 15 components, though its lightweight construction potential is relatively low due to the small number of substituted components. Strut braces are made on die casting machines with a clamping force of 2,000 to 3,000 tons, while rear longitudinal members, which offer a higher degree of substitution and greater lightweight potential, require larger machines of about 4,000 tons.
If the aim is to substitute as many components as possible, the one-piece rear end is the right choice. Here, 80 to 100 components can be substituted. These so-called gigacastings are produced on systems with a clamping force of more than 8,000 tons. However, this is not necessarily the solution with the greatest lightweight construction potential. In order to be able to produce the component by die casting, the sheet metal surfaces shown in red in the diagram below, such as the trunk floor or the wheel arches, must have a certain minimum wall thickness. This is often greater than the wall thickness required by the loads and therefore increases the overall weight of the components. The additional weight is also accompanied by higher material costs, as the expensive lightweight material aluminum is used in areas that could also be represented by a thinner, e.g. formed sheet metal component.
It will be crucial to use the right material with the right manufacturing process in the right place (topology-optimized). The sweet spot of weight and degree of substitution is seen in components that are produced on die casting machines between 4,000 t and 6,000 t.
How this can be achieved in detail has not yet been specifically outlined. Preparations are being made to make the infrastructure and energy availability possible. However, it remains to be seen whether this will be achieved despite the already known crises and possible new risks. It is not yet possible to confirm when and where green hydrogen will be available. The simplest way to reduce energy and CO2 emissions by 50% would also be to reduce production by 50% and consumption by 50%. However, this idea is in conflict with the desire for prosperity and growth of many people and companies.
The question arises: What can already be done today to reduce greenhouse gas emissions and energy consumption without the availability of green hydrogen?
The lecture at the 23rd Die Casting Day [2] in Nuremberg at EUROGUSS 2024 and this article are intended to provide ideas and incentives to deal with the topic and implement energy savings with methods and means available today [3, 4], i.e. even without green hydrogen.
Relocating production and simply waiting are not an option
The following scenarios would not be good for our climate: 1. production is relocated abroad because energy is cheaper there and there is less cost pressure due to climate protection. 2. wait until green hydrogen is available to everyone. In both cases, no improvements for climate protection would be achieved from a global perspective.
The die casting industry and all other energy-intensive industries in Germany and Europe suffer particularly from high energy costs and climate protection levies. As a result, there is already a need for action today.
In the die casting industry, solid metals are melted until they have the desired characteristics as liquid metal so that they can be molded in die casting machines. These metals are often melted down in fossil-fired melting furnaces. In some cases, the operators of the melting furnaces know the characteristics of their melting process well and are well-informed about their position in terms of energy efficiency, productivity and emissions compared with other melting processes. When this is not the case, a comparison can be an eye-opener. It reveals the current situation and what still needs to be done to achieve the targets set out in the Climate Action Plan 2050.
The melting of solid aluminum takes place during the melting process in a smelting furnace. Benchmarking natural gas-fired smelting furnaces can help to further understand how good the technology used is. The melting process consists of several process steps such as: Charging, melting, superheating, possibly alloying and casting or transfer. From the energy input and the melting rate, characteristic values can be determined which are comparable.
For this comparison of melting processes, it is rarely sufficient to compare the melting furnaces of the own plant with each other and derive measures from this. Rather, it makes sense to look and ask yourself the question: What is being done differently and better elsewhere and how can I, as operator of my own melting furnaces, achieve this? What are the limits of my melting process? To what extent can the process be further improved using conventional methods? Every refitting and every modification costs money, so it is important to act in an informed and forward-looking manner. Every investment should be justified by a profitability analysis.
Summary
The requirements of the Climate Protection Plan 2050 create many tasks and questions for the die casting industry in Germany. The German government leaves no doubt that the targets will be achieved. Higher energy costs and climate taxes are to be expected in the future. The resulting pressure on producers of die-cast parts to act is not an invitation to wait and see. The target of reducing greenhouse gas emissions by around 50% by 2030 can already be achieved with conventional measures to increase energy efficiency. Even without green hydrogen.
A contribution by Dr.-Ing. Thomas Niehoff
Moreover, while evaluating lightweight potential, other factors such as the requirements for heat treatment and the availability of repair solutions, which are limited for large castings and often costly, must be considered. Logistic costs also rise with increasing component size, suggesting that the foundry might need to integrate more closely with the vehicle plant to justify investment in new die casting systems. The number of systems required largely depends on the vehicle plant's output and the number of variants per line. Several die casting machines are often necessary to ensure a reliable supply to the vehicle line. Due to the large size of components, increased tool wear is expected, leading to more frequent maintenance and a higher number of tools required.
It should be noted that there are currently no compelling advantages for using casting cells with a clamping force greater than 6,000 tons at BMW. The BMW component plant in Landshut operates with a strong supplier network, ensuring the supply to the vehicle plants. At BMW, the focus is more on achieving optimal results with innovations and a great deal of expertise while casting the right material in the right place using the right process.
About BMW Landshut:
At BMW Group Plant Landshut, approximately 3,700 employees produce engine, chassis and body structure components from light metal casting, plastic components for vehicle exteriors, carbon body components, cockpit and equipment scopes, engines and drive shafts. The Landshut plant is the BMW Group's largest component plant worldwide and supplies components to all BMW Group vehicle and engine plants worldwide - and thus for almost every BMW, MINI, Rolls-Royce and BMW Motorrad. The BMW Group Plant Landshut stands for component production characterized by digitalization and sustainability as well as responsible use of resources.
With future-oriented technologies, the BMW Group Plant Landshut plays the role of an innovation driver in the technological transformation of the automotive sector and its supplier industry. At the Lightweight Construction and Technology Center (LuTZ), which is directly connected to the plant, specialists from a wide range of disciplines actively drive the sustainable development of future vehicle models. They are involved in the development processes of new vehicles at an early stage. The BMW Group Plant Landshut is a socially responsible, innovative and attractive employer in the Landshut and Lower Bavaria region.
About Dr. Thomas Kopp and Klaus Sammer
Klaus Sammer has been part of the BMW Group since 1985 and was most recently Head of Planning for Painted Bodywork at the Dingolfing plant and, from 2018 to 2021, Head of Painted Bodywork for the plant under construction in Debrecen (Hungary). He then took over the management of product and process planning for the light metal foundry at the BMW Group plant in Landshut. In addition to his duties in the BMW Group, Sammer is also a member of the advisory boards of various associations.
2001 to 2005: Project Manager - Plant Munich BMW
2005 to 2011: Team Lead Research Development - Plant Munich BMW
2011 to 2015: Head of the department for assembly and total vehicle validation - Plant Munich BMW
2015 to 2018: Head of Planning Body Shop - Plant Dingolfing BMW
2018 to 2021: General Manager Pressshop and Bodyshop - Plant Debrecen BMW
2021 to 2023: Head of Technology Center Foundry, Plant Train Construction, Maintenance and Prototype Construction as well as Product & Process Planning - Plant Landshut
Dr. Thomas Kopp has been with the BMW Group since completing his doctorate in 2016. He is currently responsible for the further development of innovative cast components for future vehicles as Team Coordinator Advanced Development in the Light Metal Casting Technology Center. Previous positions include sub-project manager for production and team leader for quality in gravity and low-pressure casting. In addition to his work at the BMW Group, Dr. Thomas Kopp is also a member of the advisory boards of various associations.
Conclusion
In conclusion, the EcoSpray system proved to be an efficient and environmentally friendly solution for die casting foundries looking to improve their production processes. The technology's ability to reduce cycle time, consumption, and energy use, as well as improve casting quality and die lifetime, makes it an attractive solution for foundries looking to reduce their impact on the environment and achieve cost savings.
Cutting, deburring, cleaning and surface treatment
Building on this foundation, SIR Spa's robotic solutions extend to an array of specialized applications in foundry processes. These include the cutting, deburring, and cleaning of aluminium castings, ensuring a smooth finish and precise dimensions. In the realm of iron castings, their robots adeptly handle cutting, deburring, and finishing, reflecting a high level of attention to details.
For die-casting operations, SIR Spa's robots excel in tending die-casting units, as well as in the critical task of die-cast casting risers removal. This precision work ensures the integrity and quality of the final product. The challenging process of sand flogging, vital for mold preparation, is also efficiently managed by these advanced robotic systems.
Furthermore, the handling and gluing of cores, a task demanding utmost accuracy and consistency, is seamlessly executed by SIR Spa's robots. Their involvement in gravity casting processes showcases their ability to adapt to different casting methods, maintaining high efficiency and product quality.
Finally, SIR Spa's expertise in foundry automation is a testament to their innovative approach. They provide solutions that encompass the entire spectrum of foundry operations, ensuring that every aspect of production benefits from automation's precision, speed, and reliability.
But SIR Spa's commitment goes beyond just supplying robots. They are a partner in progress, offering comprehensive support from initial consultation to post-implementation maintenance. Their team of experts is always on hand to ensure that each robotic system operates at its peak, delivering consistent value to your foundry operations.
In a world where efficiency and quality are the currencies of success, SIR Spa is your trusted ally. Explore the future of foundry with SIR Spa's robotic solutions and witness a transformation in your production capabilities, safety standards, and overall operational excellence.
Don't let the future pass you by. Contact SIR Spa today and step into a new era of foundry innovation.
Discover More About SIR Spa's Foundry Solutions: https://sir-mo.it/en/foundry
Figure 1 shows the principle of the new circulation dosing system. If there is no request from the mixer (9), the slip is kept in circulation by the circulation pump (2) so that the components of the slip remain homogeneously mixed. As soon as there is a request for binder dosing, the circulation pump stops. Valves 3 and 8 close and valve 6 opens. The dosing device is actuated by the actuator (5) and the slip is dosed into the mixer via valve 6 and the dosing bolt. When the required dosing quantity is reached, the actuator stops and valve 6 closes. Valves 3 and 8 open, the circulation pump starts again and the actuator returns to the starting position. The device is now ready for the next dosage.
The proven and well-known product range of bellow dosing equipment from KLEIN Anlagenbau AG has now been extended to include the new BDG-ULD recirculating dosing device. The BDG 254-ULD can reliably and reproducibly dose slip amount of 12.5 to 220 grams per dosing process with an accuracy of ± 0.6% (FS). The BDG-ULD can be equipped with a flow control upon request and features a user-friendly multi-point calibration integrated into the control. It is fully automated and can be integrated into existing binder dosing systems.
The BDG-ULD has proven itself at Hansgrohe SE. In its endeavour to produce its world-famous products sustainably, Hansgrohe is now using eco-friendly binders from Reinsicht with success. Step by step, the proportion of inorganic binders is now to be further increased. Figure 2 depicts a BDG-ULD in continuous industrial use.
With the development and confirmation of BDG-ULD in continuous operation, the eco-friendly binder from Reinsicht GmbH and the tailor-made bellow dosing equipment BDG-ULD from KLEIN Anlagenbau AG are now available for general use.
This can be particularly interesting not only for smaller foundries. Often, the desire for innovation and implementation of existing ideas has to be put aside for reasons of capacity utilization. Reinsicht and KLEIN Anlagenbau AG offer a low-threshold entry point here by providing binders and mixing technology ready for in-house trials and using their expertise to develop optimal solutions on site together with the process operators. This approach can achieve both environmental protection and economic efficiency. Contact us - we look forward to hearing from you!
After the rebuild phase, the spray tool was also flushed, cleaned and fitted with adapter modules to achieve a spray distance of less than 150 mm. All Wollin SD nozzles were removed and replaced with Wollin FSD nozzles. Except for 2 KD-A-06 ball nozzles, only KD-A-L-08 and KD-A-L-10 were installed.
To complete the installation during the shutdown, Waupaca Foundry depended on collaboration with contractors Beson and Houle and IVI, as well as in-house engineering and maintenance.
“It was a huge advantage to have home-grown engineers,” said Rob Jezwinski, Waupaca Foundry engineering manager. “We live in this environment, so we were intimate with the details needed to create an efficient process and install an entirely new operating system for Christmas.”
The old shaker system was prone to gating jam-ups, which shut down all molding lines for repair. The Magaldi Superbelt conveyors improve gate and sprue transportation uptime, reduce energy costs, and reduce maintenance costs—all in all, improving quality and delivery performance to Waupaca Foundry customers. Equally important, the new conveyors improve the foundry workplace because they run more quietly and improve indoor air quality.
“The safety benefits of the new system were as important as the bottom-line savings,” Osborn said. “By replacing the vibrating system, we significantly reduced the amount of airborne dust and created a healthier working environment for our team.”
According to representatives from Magaldi, the system has innovative features that are equipped to transport large volumes of gating and sprue material.
“Because our system does not vibrate, the iron returns do not collect and jam up, silica dust is not generated, and the system is very quiet,” said Brandon Kruse, general manager of Magaldi Technologies. “To minimize energy consumption, we can speed up or slow down the conveyor if we notice heavy tonnages because there’s an advanced algorithm in the system that tracks scrap loading on all six lines.”
This is the second major capital project at the Marinette, WI ductile iron foundry in recent years. Plant 4 completed a multiyear power service upgrade in 2023. The plant is 327,000 square feet and can run six different grades of ductile iron concurrently using eco-conscious electric melt technology.
About Waupaca Foundry, Inc. Waupaca Foundry, Inc., North America’s leading supplier of iron castings to the automotive, commercial vehicle, agriculture, construction, and industrial markets, produces gray iron castings, ductile iron castings, and austempered ductile iron castings using state of-the-art processes and technology. The manufacturer also specializes in precision machining and assembly. Waupaca Foundry is Headquartered in Waupaca, Wisconsin and operates six iron foundries located in Waupaca, Wisconsin, Marinette, Wisconsin, and Tell City, Indiana. The company operates machining and assembly in Waupaca, Wisconsin. Waupaca employs approximately 4,000 people. For more information, visit www.waupacafoundry.com.
About Magaldi Technologies: Magaldi Technologies (www.Magaldi.com) is the US branch of the parent company Magaldi Power SpA located in Salerno, Italy. The Magaldi group companies started in 1929 and is the world’s leading manufacturer of steel belt conveyors to handle materials in severe conditions - including high temperature, abrasive and heavy materials - used in foundries, coal-fired power plants, steel mills, mineral processing plants, cement plants, waste-to-energy plants and solid-fuel power plants, with more than 1,500 installations worldwide. Magaldi Group’s mission is to design, manufacture and market reliable, high quality systems which are able to provide environmentally sustainable industrial solutions worldwide. Based on its patented technologies, Magaldi produces highly automated systems able to reduce costs and achieve the highest level of quality in accordance with the principal standards. Its products are distributed worldwide through subsidiaries and licensees.
The German-speaking foundry world faces major challenges in 2024. While some segments are experiencing a remarkable upswing, others are facing increasing pressure from new competitors and products, changing supply chain structures and new business potential. Against this backdrop, strategic priorities need to be adjusted.
On behalf of the Austrian, Swiss and German foundry associations, Salzburg will once again become the center of the German-speaking foundry world on 25 and 26 April 2024.
The "Große Gießereitechnische Tagung 2024" will be an important forum for the exchange of information and experience for foundrymen, casting users and the supply industry.
In the lead up to the event, we want to take a look at the different regions and have interviewed those responsible at the associations:
DI Christa Zengerer
Managing Director OGI, Austrian Foundry Institute
Marcel Menet
Managing Director Foundry Association of Switzerland GVS
Max Schumacher
Managing Director BDG, Federal Association of the German Foundry Industry
Lifetime Legacy Sponsors
The WFO is proud to count on the support of some leading companies for the organization of this virtual conference, along with the continuous support of its Lifetime Legacy Sponsors.
Regeneration plants close to foundry sites
The service model is simple: FSP operates regeneration plants near foundry sites, collects the used sand from the foundries, regenerates it and returns the sand to its customers. The process technology used ensures that there is no mixing of the regenerates, and that each customer receives the regenerate from their used sand.
Sand in the cycle
The basis of regeneration at FSP is the wet regeneration process for used sand bound to water glass. Used sand, which has been in use in the pilot plant at the Stuttgart site since 2022 and has and has passed the acid test. For the regeneration of organically bound sands, FSP will also operate an additional pilot plant from May 2024, which will which has mechanical-thermal stages. The quality of both regenerates is equal to that of virgin sand: they substitute it by around 95 per cent.
On the one hand, FSP's service model relieves customers of the need to invest in the plant components required for the connection to the regeneration process. Depending on the process and binder system used, these include sand dryers, lump breakers, screens, magnets for removing metallic particles or cooling systems for the regenerated material after regeneration. On the other hand, many activities associated with the disposal of untreated used sand, waste and, above all, the dumping of dust are eliminated. Compared to an in-house plant, the operator model frees up personnel capacities in the area of plant operation and avoids cost-intensive maintenance and stockpiling of spare parts. In addition, the foundries do not have to go through any authorisation procedures.
FSP takes over the disposal of all residual materials
In contrast to models where plants are built on the premises of a foundry or for which a price is payable per month for a tonne of processed sand (pay-per-use) in addition to a rental fee, FSP also takes care of the delivery and removal of both the used sand and the regenerated sand. In addition, FSP takes care of the disposal of all residual materials produced during regeneration, in particular the dust produced. It is analysed at FSP and, if possible, supplied to other industries as replacement material. In this way, the dust also becomes recycled material.
Overall, FSP significantly reduces the material flow in the customer's plants, not only in terms of the amount of waste, but also in terms of plant transport. In addition, the model avoids empty runs for the delivery and removal of materials, as every lorry and every freight wagon that collects used sand from a foundry is loaded with reclaimed material. At the Stuttgart site, it can even be supplied by rail and ship.
FSP disposes of all waste produced during reclamation via a certified disposal route via Heinrich Feess GmbH & Co. KG in Kirchheim/Teck, the shareholder of FSP. This reliefs customer of the need to build up and maintain their own personnel capacities for waste disposal. Customers are also relieved of the burden of working with environmentally harmful materials.
Both the reclaimed material and the fines produced during regeneration correspond to landfill classes DK 01 or DK 02, which can be disposed of at lower costs. This means that the operator model also pays off for foundries that cannot reuse the sand due to special processes.
The reclaimed material also offers the possibility of utilising other disposal methods: The EU standards that will apply in the future state that reclaimed sand can be reused more easily in road construction, as an additive in the production of cement and gypsum or in the glass industry. Nevertheless, the primary aim of regenerating used sand must be to reuse the regenerate in a continuous cycle - this is the only way to ensure responsible and future-proof handling of sand as a natural resource.
The operator model in practice
FSP is pursuing a concrete roadmap: The pilot plant for wet reclamation, which has been in operation since 2022, will be expanded to a throughput of 2.5 tonnes per hour, i.e., around 20,000 tonnes per year. A further pilot plant for mechanical-thermal regeneration with a capacity of around one tonne per hour is under construction and will be available to customers for test series and open-loop processes from May 2024.
FSP will also install a mechanical-thermal system with a throughput of six tonnes per hour, i.e., around 70,000 to 75,000 tonnes per year, at its headquarters in Stuttgart in the course of this year. It will be ready for series production at the beginning of 2025 and will primarily supply foundries in the greater Stuttgart area and the rest of Baden-Württemberg.
FSP is also planning to open two to three further sites in the near future, each of which will serve other foundries within a radius of 200 to 300 kilometres. They will each have a capacity of around 180,000 to 200,000 tonnes of used sand per year.
Both test facilities will be available to foundries from May 2024. They can be used to test and analyse the regenerability of inorganically or organically bound sands, or even mixed sands. FSP offers interested customers a range of different tests - from a simple test series with up to 1 tonne of sand to a complete free-running process with determination of the best possible ratio of reclaimed and new sand in core production. At the end of the tests, the customers receive the reclaim, dust and waste backpacked in big bags. This allows them to draw conclusions about the composition of the reclaim, for example the ratio of reclaim to fines and residual materials.
The main quality characteristics relevant to both binder systems (inorganic and organic) are determined in the in-house sand laboratory: Fines content and AFS number, active clay and slurry content, pH value, residual alkalinity, electrical conductivity, loss on ignition, strengths, and core weight.
For the test series and in subsequent series operation, sand samples are analysed on delivery of the used sand and on delivery of the reclaimed sand. The quality is recorded and documented online during series operation of the reclamation plants. This prevents deviations from the agreed quality criteria of the reclaimed sand. External laboratory facilities can also be consulted.
INFO: The technology in detail
The following applies to both reclamation variants: the used sand can be delivered in both silo and skip lorries. The complex plant and process technology ensures that the used sand - before it is fed into the actual reclamation process - is free of foreign materials, scrap metals and lumps and is dry and free-flowing. After reclamation, the reclaimed material is conveyed into outdoor silos and is ready for transport in silo lorries for collection.
In order to minimise the customer's handling costs, any necessary adjustments at the customer's plant to ensure a smooth and consistent supply of reclaim are clarified together on a case-by-case basis and implemented on site.
FSP's globally patented process for the wet regeneration of inorganically bonded core sands washes 98 per cent of adhering residues from the used sand. All common water glass-bonded used sands as well as special sands from 3D printing can be fully processed.
In the patented drying system, the sand is not dried with air, but the moisture is extracted from it in an energy-efficient manner through condensation. The sand is then cooled in a separator with patented fluidisation and additionally dedusted.
In principle, washing is the gentlest option for regenerating inorganic binders, as there is no direct mechanical impact on the sand grain. As a result, no additional dust is formed apart from the fines that are already contained in the used sand and are washed out. The process water required for the washing process is 100% treated and kept in a closed circuit. Binder components and waste from the casting process are completely washed out and removed from the process as sludge via the water treatment system. The resulting waste is disposed of in a certified process and the correct treatment is documented.
With mechanical-thermal regeneration, FSP is also setting new standards in the field of regeneration using series systems with medium and high throughput rates. The process can be used for both bentonite-bound green sand and organically bound core sand (cold box, hot box, shell sand, furan). Compared to conventional mechanical or purely thermal regeneration processes, the process technology reduces the dust content to a minimum.
Thermal-mechanical regeneration is characterised by the high efficiency of the three-stage system. After pre-treatment of the used sand, the sand is fed dry and free-flowing to the first - mechanical - stage, in which sand grain by sand grain and thus the binder is removed.
In the second stage, the sand is fed to the thermal stage. Gas and air mix in a sand bed, it fluidises, and the organic binder and fines are burnt. The effect of the quartz cracking loosens any remaining binder from the natural recesses of a grain of sand or even blasts it off. In the third, also mechanical stage, the last residues are rubbed off the grain; it works in the same way as stage one.
Providing information on site
In June 2024, FSP will be organising an "open week" at the Stuttgart site: Interested parties can visit all the plants and see for themselves both the efficiency of the two regeneration processes and find out about the advantages of the operator model.
About the FSP Gmbh
Founded in Stuttgart in May 2022, FSP GmbH Foundry Sand Processing develops and sells systems and solutions for the regeneration and processing of bulk materials. The basis is decades of experience in the recycling of raw materials and the mechanical-thermal or wet regeneration of used foundry sands. The founding partners are Heinrich Feess GmbH & Co. KG in Kirchheim/Teck and DEANTEC GmbH in Kirchhundem.
Feess, which was awarded the German Federal Environmental Prize in 2016, proved its expertise in the recycling of mineral waste, while DEANTEC contributes its experience with its unique, patented wet regeneration and drying process - a plant technology that uses exclusively renewable energy in the processing of used sand.
The merger to form FSP GmbH offers customers the complete, almost CO2-neutral sand processing chain. The regenerated material replaces up to 95 per cent of new sand and makes an important contribution to the conservation of resources and sustainable production.
Author: Dipl.-Oec. Stefan Zimmermann, Managing Director, FSP GmbH Foundry Sand Processing, Stuttgart
1) How do you evaluate the current situation in the foundry industry in your country?
Christa Zengerer
The current situation in the foundry industry in Austria is characterized by various challenges. Due to global economic uncertainties and increasing regulations, companies are facing challenges such as rising costs for energy and raw materials, as well as increased competitive pressure from abroad. Nevertheless, there are also positive aspects, such as the efforts of many companies to introduce innovative technologies and optimize production processes.
Marcel Menet
As many Swiss foundries are heavily export-oriented, the outlook depends largely on the economic development of our key target markets such as Germany and France. The persistently strong upward pressure on the Swiss franc is causing price rises in exports that cannot be compensated for in the short term and are therefore weighing heavily on the export business. We anticipate a further slowdown in the coming months. According to some major customers, a recovery is not expected until the second half of the year and demand will pick up again, in some cases stabilizing at a low level.
Max Schumacher
Production fell by 1.6% overall in 2023 - a very weak end to the year. And the economy is not gaining momentum in the first few months of 2024 either. The foundry industry is currently in rough waters. Whether and to what extent it will be able to pick up in the second half of the year is difficult to predict due to the geo-economic and federal political conditions. The discussions I have had with foundries so far also show that their annual planning is fraught with massive uncertainties. Politicians are increasingly and urgently being called upon to provide planning certainty.
It is generally expected that interest rates will be gradually lowered in the second half of the year. This would have an impact on the willingness to invest in general and, of course, on the construction industry in particular. Foundries could also benefit from possible effects on customer industries, meaning that the 5% for the foundry industry could still be exceeded by the end of the year.
Christa Zengerer – "We need to reduce bureaucratic hurdles and high taxes and I call for better coordination between companies, government and educational institutions on an ad hoc basis"
Max Schumacher – "We need planning security, Germany's energy-intensive SMEs are committed to the location and to ecological, economic and social sustainability. With our products and innovations, we are driving the transformation and enabling climate protection and decarbonization."
2) Companies in the entire foundry sector are currently struggling with various uncertainties. Which obstacles and uncertainties could be improved immediately by creating good location conditions at national and European level? What are your ad hoc demands?
Christa Zengerer
In order to improve the conditions for the foundry industry both nationally and Europe-wide, it is crucial to remove obstacles such as bureaucratic obstacles and high taxes. A good infrastructure, access to a skilled workforce and a supportive research and innovation landscape are also important. Ad hoc, I call for better coordination between companies, the state and educational institutions in order to improve the training and qualification of skilled workers and drive innovation.
Marcel Menet
Swiss foundries are currently concerned about the sustainable pricing in of energy taxes - in addition to the general rise in prices. This requires finesse in discussions with customers.
Added to this are the effects of the interventionist policies of the major economic blocs USA, China, and EU. Europe is forced to compete with the USA and China in terms of subsidies, otherwise companies will move away due to the disadvantages of the location. A small country like Switzerland has only limited opportunities to participate in this subsidy competition.
In addition, the European intervention policy in particular, under the guise of the "European Green Deal", also distorts the markets and thus the price structures. It would be desirable for Switzerland to react to these distortions, be it through subsidy programmes for energy-intensive industries or, for example, an industrial electricity price.
Max Schumacher
Companies in the foundry industry - like companies in other industrial sectors - need planning security. Quick and decisive political action is required to restore the competitiveness of German industry. Germany's looming decline as an industrial centre has serious consequences for general prosperity, the supply of important products, the transformation to climate neutrality and the future viability of society. To be clear: German industry is behind the transformation to climate neutrality in the face of climate change. It wants to decarbonise its production processes as quickly as possible and sees itself as an active enabler of the transformation. However, this is a task of the century that can only be accomplished with a powerful and internationally successful German and European industry. Germany's energy-intensive industrial SMEs are expressly committed to Germany as a business location, to ecological, economic, and social sustainability and thus to comprehensive corporate responsibility. With our products and innovations, we are supporting the transformation and enabling climate protection and decarbonisation.
However, the question for us is: Is industrial production - explicitly including energy-intensive industrial SMEs - still wanted in Germany? Society and the administration need to rethink: allowing, not preventing, value-adding industrial production as the basis for jobs and prosperity in all parts of Germany is the order of the day. Our demand to politicians is therefore specifically aimed at setting a fundamental political course that relieves the burden on companies. And the instruments that have been created so far for the transformation must be scrutinised to see whether they really help to promote climate protection or whether they merely mean more effort and cost.
We have therefore founded the Alliance for a Fair Energy Transition (BfE) together with other associations and have summarised our demands for German industry in a manifesto. It can be downloaded at A manifesto for small and medium-sized industry! (faire-energiewende.de). Political decision-makers at federal, state, and municipal level are called upon to make a clear commitment to Germany as an industrial location.
3) The German-speaking countries play a leading role in the foundry industry in Europe and the world. What trends with positive development opportunities do you currently see and what will become established?
Christa Zengerer
There are some positive development opportunities in the German-speaking foundry industry. These include, for example, the increased use of digital technologies such as 3D printing and the simulation of cast components and processes in order to increase production efficiency. Environmentally friendly production methods and materials could also become more important. These trends are likely to become more prevalent as they offer both economic and ecological benefits.
Marcel Menet
Decarbonisation is a major challenge for the entire industry and society in general. It is therefore not surprising that a great deal of innovation is taking place in the area of sustainability. For example, some foundries want to replace natural gas and oil with CO2-neutral energy sources. There are concrete projects to replace them with electricity, while the use of hydrogen is still more in the idea phase. In general, the trends in climate protection and individual mobility towards lightweight construction are fuelling the growing demand for sustainable and innovative casting solutions.
Max Schumacher
The high standard of education and interdisciplinary expertise in research are a very clear and major advantage for the German-speaking countries, resulting in their leading position in the development of key technologies. In combination with an excellently positioned SME sector, they secure their technological sovereignty in international competition.
Green production, the circular economy and sustainability are increasingly becoming the boundary conditions of the global economy. This is likely to lead to the permissible limits for the CO2 footprint or similar being tightened further. In German-speaking countries in particular, intensive work is therefore already underway on technological solutions. An even stronger interlinking of innovative areas such as AI, material science and industrial engineering is clearly recognisable.
Pooling this expertise makes it possible to develop new materials and processes with intelligent design and combine them in such a way that the boundaries of lightweight construction can continue to be pushed - while at the same time taking sustainable production processes into account. Automotive and energy are strong drivers here. We are technology leaders and I still see a lot of development potential here. And the foundry industry in German-speaking countries will play a key role.
4) How can locations be retained while at the same time making them fit for transformation and digitalisation and countering the shortage of skilled workers? Will good training and experience be enough, or will the offerings become even more interchangeable in the future?
Christa Zengerer
A comprehensive strategy is crucial to maintaining locations and preparing them for the challenges of transformation and digitalisation. In addition to sharpening the skills and experience of employees, increased investment in research and development is essential. The importance of innovation lies in helping companies to remain competitive and enter new markets. It is also important to offer attractive working conditions and development opportunities in order to retain skilled workers in the long term and encourage their commitment. In addition, flexible working models and the use of digital platforms to network skilled workers can help to alleviate the shortage of skilled labour. Overall, a combination of investment in R&D, employee development and the creation of a flexible working environment is crucial to successfully meeting the challenges of the future and ensuring long-term competitiveness.
Marcel Menet
IT security, digitalisation and automation are being driven forward in Swiss foundries thanks to intensive employee training. The ongoing shortage of skilled and unskilled labour remains a Herculean task this year. Massive management and employee training programmes are required, as specialist and management expertise is needed both in breadth and depth to ensure that complex components can be manufactured stably using highly automated processes.
Max Schumacher
We could organise a separate specialist conference on the subject of skilled workers, so I will just make a few comments here: What is certain is that interchangeability is precisely what we can and must set ourselves apart from. We are technology leaders and must work hard to remain so in the future. I have just explained this. As an association, we are active in all the areas mentioned above in order to provide support to the industry.
Some examples: With the ReGain project we are trying to integrate AI into many areas of the casting process. The industry must distinguish itself as an attractive employer in order to stay ahead in the competition for employees. Since casting is an essential part of the transformation, we can, for example, safely meet the young generation's desire to not just do a job with work, but to make meaningful, sustainable contributions. This ensures that we have motivated employees who set us apart from the crowd and are not replaceable.
Marcel Menet – "The most important industry meeting of the D-A-CH foundry industry should be a sign of new beginnings"
5) What impulses do you expect from the large foundry technology conference in Salzburg? Do you have a personal wish?
Christa Zengerer
I hope that the large foundry technology conference in Salzburg will enable a lively exchange between all players in the foundry industry. In addition to my expectations of a lively exchange of knowledge and experiences, I also hope for a pleasant and sociable event where participants can network and chat in a relaxed atmosphere.
Marcel Menet
It meets a great need in the industry to be able to exchange ideas, especially in difficult times. The most important industry meeting for the D-A-CH foundry industries should be a sign of new beginnings!
Max Schumacher
First of all, I'm looking forward to bringing the foundries from German-speaking countries together in the great Salzburg atmosphere so that they can exchange ideas freely. The program is also promising. It spans a wide range from interesting contributions on foundry technology to important impulses on sustainability issues and the circular economy to panel discussions. I am personally particularly looking forward to the exciting keynotes at the beginning and end of the conference. That should not be missed. The exhibition is also well booked and will give rise to many specialist discussions. Did I already mention that the foundry evening will once again be a highlight? I think so, but that can't be mentioned often enough
What am I looking forward to? On showing a traditional industry in stormy times its opportunities, relevance, and potential, and on uncompromisingly demanding a commitment to local casting.
My personal wish is that when I leave, I can take with me the participants' strong recommendation to repeat this meeting as soon as possible. I am in!
Glück Auf!
Designed by: Maximilian Schröck – Foundry-Planet GmbH
Images of the experiment
In the test, sufficient die temperature control was achieved by minimum quantity application with the release agent HERA™ light Chem-Trend® SL-68504 diluted 1:5.
In summary, it can be said that for successful performance of minimum quantity application, a water-operated heating-cooling unit is necessary for sufficient die temperature control. Approximately 200 shots were fired in the test, and after adjustment of the nozzle orientation, the separation effect could be judged to be good. The part surface showed slight streaking, but was good according to Fritz Schmidt's quality assurance department. Dimensional accuracy was also within tolerance.
All defined targets could be achieved with the minimum quantity application process.
By using it with a simple, standard die temperature control system, the minimum quantity application process achieved energy savings of 72% for the heating/cooling equipment.
By reducing the quantity of release agent spray, the consumption of release agent concentrate was reduced by ~60%, and the lower release agent application reduces the thermal load, which means that a longer die service life can be expected.
In addition, the use of MQA technology has reduced the cycle time by 18%. This means that more parts can be produced in the same time, which leads to an increase in output.
Another goal of the trial was to reduce water consumption and wastewater disposal costs. By using Wollin EcoSpray technology, water consumption was reduced by 97%, resulting in significant cost savings. The costs for wastewater disposal are eliminated completely.
The reduction in compressed air consumption also led to a reduction in noise emissions, which improved working conditions in the foundry. The shorter spray/blow time at lower pressure reduced compressed air consumption by ~ 76%.
Comparison of conventional spraying and minimum quantity application at Fritz Schmidt
Conclusion
Overall, the use of MQA technology in combination with the water-based release agent HERA™ light Chem-Trend® SL-68504 resulted in significant cost savings and productivity improvements.
The trial shows that even a simple die tempering system of standard design can be suitable for the use of minimum spray technology when combined with the right equipment and technology.
In conclusion, it can be stated that Fritz Schmidt Metallgießerei GmbH & Co. KG was able to increase productivity and reduce costs by using MQA technology and the water-based release agent HERA™ light Chem-Trend® SL-68504 . The trial shows that it pays off to use innovative technologies in the foundry industry to produce more economically and sustainably.
About STIHL:
The STIHL Group develops, manufactures, and sells power tools for forestry and agriculture as well as for landscape maintenance, construction, and private garden owners. The product range is complemented by digital solutions and services. The products are generally sold via service-providing specialist dealers and STIHL's own online shops, which will be expanded internationally over the next few years - with 42 own sales and marketing companies, around 120 importers and more than 55,000 specialised retailers in over 160 countries.
STIHL produces in seven countries worldwide: Germany, USA, Brazil, Switzerland, Austria, China, and the Philippines. STIHL has been the world's best-selling chainsaw brand since 1971. The company was founded in 1926 and is headquartered in Waiblingen near Stuttgart. STIHL achieved a turnover of 5.49 billion euros in 2022 with 20,552 employees worldwide.
[FP]-LIMS Software: The standard LIMS for foundries
[FP]-LIMS stands out as the standard Laboratory Information Management System in the foundry sector, distinguished by its unique selling propositions (USPs) that cater specifically to the needs of foundries. Key among these is its unparalleled adaptability to various foundry processes, allowing for seamless integration with existing systems and machinery. This flexibility ensures that [FP]-LIMS can handle diverse types of data, from raw material inputs to finished product quality assessments. Additionally, its user-friendly interface simplifies complex data management tasks, making it accessible to personnel at all levels of technical proficiency. Another major USP is the software's robust data security features, ensuring that sensitive information remains protected, which is critical in industries like nuclear technology.
Furthermore, [FP]-LIMS enhances traceability of products from start to finish, providing a comprehensive audit trail that is vital for quality assurance and regulatory compliance. Lastly, its advanced analytics capabilities empower foundries to make data-driven decisions, optimizing processes, and reducing waste, thereby contributing significantly to cost savings and environmental sustainability. These features collectively make [FP]-LIMS an indispensable tool for modern foundries seeking to enhance efficiency, reduce costs, and maintain a competitive edge in a challenging industry.
Real-life Examples of Foundries Saving Costs with LIMS Software
Many foundries have already embraced [FP]-LIMS software and achieved remarkable achievements. Let's highlight a couple of real-life examples that demonstrate how this technology can revolutionize foundry operations. One of them is Siempelkamp Foundry.
Siempelkamp Foundry: LIMS proves itself in practice for 30 years
The introduction of LIMS software by Fink & Partner at Siempelkamp Foundry, a globally renowned manufacturer of large and heavy castings made of nodular graphite cast iron, has significantly contributed to the optimization of their complex casting production. Over the course of 30 years, LIMS from Fink & Partner has established itself as a reliable system for managing and evaluating chemical analyses. Every day, about 60 analyses are conducted in the laboratory, which automatically feed into the LIMS and are thus also communicated in the melting shop. This substantially aids in quality assurance for the highly precise production processes required for the manufacturing of large castings weighing up to 320 tons.
Read success story: https://www.fp-lims.com/en/siempelkamp-foundry/
Recommendations and Conclusion
Implementing LIMS software in foundries is a strategic investment that has a lasting impact on cost savings and operational efficiency. To fully reap the benefits of LIMS software, it is crucial to choose a solution that is tailored to meet the specific needs of the foundry industry. Foundries considering the adoption of LIMS software should thoroughly evaluate their requirements and select a reputable vendor with proven experience in the industry.
In conclusion, LIMS software provides foundries with the tools necessary to achieve long-term cost savings while boosting operational efficiency. By streamlining workflows, optimizing inventory management, ensuring quality control, enabling real-time analytics, centralizing data, and enhancing traceability, LIMS software revolutionizes the foundry industry. Foundries that embrace this technology position themselves for success, reducing expenses, and elevating their overall competitiveness in the market.
Download the whitepaper “The future of foundry labs: Efficiency and precision with [FP]-LIMS” now: Whitepapers - foundry-planet.com B2B Portal
Book your personal [FP]-LIMS demo: https://www.fp-lims.com/en/lims-software/demo/
HWS test plant for sand reclamation
In its in-house test plant, HWS offers interested foundries the opportunity to convince themselves of the efficiency of used sand reclamation. With the USR-II machine in a near-series design, reclamation tests can be carried out under conditions that are similar to production. The focus here is on determining the suitability for reclamation and the process parameters for the conceptual design of an overall plant.
The competition entries are assessed individually in the materials and evaluated in terms of innovation, quality, cost-effectiveness, resource-efficient design and degree of difficulty. The three best entries for each material will be awarded a prize.
We need a clear statement that this industry is wanted here
As VDD President Hartmut Fischer and VDD Managing Director Thomas Krüger emphasized in their opening remarks, the competition in particular demonstrates the high performance of the European die casting industry in challenging times. Those responsible were delighted with the large number of excellent submissions to the competition.
The mood in the industry is surprisingly good, what the industry still needs now is competitive energy, a favorable investment climate and a clear statement from politicians that this industry is wanted.
Here you can see the current award winners with their exhibits: Foundry-Planet congratulates all award winners
Magnesium: Place 1
High market potential
Ibrahim Anil, Founder and General Manager of “Hannover Messe Ankiros Fuarcılık A.S.”, emphasises the advantages of the partnership:
“To ensure the continuity of the success stories of ANKIROS/TURKCAST and ALUEXPO and to institutionalise the structure, I am passing the baton to capable hands. As I continue in my role as the General Manager, I am transferring my partnership rights to Messe Düsseldorf. With Messe Düsseldorf and Deutsche Messe AG, two globally leading trade fair companies will now ensure further growth of these trade fairs. The continuously growing Turkish economy and the high demand for metallurgy and foundry products in Türkiye, the region and worldwide provide the ideal framework for this.”
Türkiye has attracted attention with its above average economic growth over the past decade.
Although factors like the pandemic and the global economic downturn have slowed this development, the International Monetary Fund expects the Turkish economy to grow by approx. 3% a year until 2028. Thanks to its large domestic market and strong industrial base, Türkiye has long been an important trading partner for Germany and North Rhine-Westphalia.
In 2022, the trading volume between Germany and Türkiye amounted to EUR 27 billion, with NRW accounting for 42.6% at EUR 11.5 billion. In addition, Türkiye has invested heavily in the construction of housing, streets, bridges and railways amongst other things over the past few years. Other major projects are under preparation. This entails a particularly high demand for metallurgy and foundry products for which the joint venture of Messe Düsseldorf GmbH and Deutsche Messe AG will organise the central marketplaces in the region. In addition, Turkish companies occupy a significant market position in the aluminium and NF-metals industries.
Watch the video of 30 Gefond at Euroguss 2024
Gefond celebrated its 30th anniversary with a stylish birthday party during EUROGUSS 2024 with customers, partners and companions.
In her empathetic and very personal speech, Tiziana Tronci described the development of the company, which was founded by her father Pierluigi. Tiziana Tronci is now leading Gefond with passion and charm at a time of great challenges and it seems that the generational change has been a success.
The guests were full of praise and enjoyed the celebration in high spirits.
The future is green hydrogen
According to the EU, renewable energy, including renewable hydrogen, is a central pillar of the REPowerEU Plan*. As well as increasing Europe’s energy security, green hydrogen is important in the EU's push for net zero emissions, with a target to achieve a reduction of 55% by 2030, compared to levels measured in 1990 (source: European Union, Energy)
Digital twin
Calderys is a key partner - and the sole supplier of refractories, in the Spain-based TWINGHY project.
As its name suggests, this project to modify the heat transfer process in reheating furnaces is being developed alongside a digital ‘twin’, which will be used to control the combustion of hydrogen and oxygen in hybrid burners. The aim of the project is to deliver significant carbon dioxide emission reductions while also saving energy and maintaining low Nitrogen Oxides (NOx) emissions.
Like HYDREAMS, TWINGHY is financed by the European Union under the Research Fund for Coal and Steel (RFCS). Initiated in the summer of 2023, the TWINGHY project will run until 2027.
Bruno Touzo: “We’ll be involved in many more hydrogen green-steel projects in coming years, as the industry moves towards the EU’s targets for zero emissions. What we’re learning with HYDREAMS and TWINGHY will eventually bring operational and cost benefits to all of our customers, and sustainability, not just in Europe, but worldwide.”
What is green hydrogen?
In industry, hydrogen is produced by the electrolysis process, which uses electricity to separate water into its constituent, atomic parts of hydrogen and oxygen. This simple, but energy intensive process allows the hydrogen to be caught and stored for use as a highly-combustible, clean-burning, and efficient fuel.
To produce green hydrogen, the electrolysis process is powered by electricity generated by renewable sources, instead of fossil fuels. If 100% renewable sources (solar, wind, and hydro) are used, the hydrogen is made with zero carbon emissions. Hence, green.
A recent collaboration by Kennametal, an industrial technology leader, and Voith, a leading supplier of drive technologies, shows how 3D printing, or additive manufacturing, offers a pathway to novel, lighter-weight tooling solutions that overcome these challenges while improving productivity and efficiency.
The Challenge: Machine multiple, tight tolerance, large diameter bores with existing machining centers
Voith wanted an innovative solution to further optimize its machining processes for transmission housings. The company needed a multi-stage tool capable of machining multiple bores in one operation to achieve the required tolerances. The tool also needed to have two effective cutting edges on the main diameters to achieve the specified cycle time. Finally, the tool had to weigh less than 12kg to meet the requirements for tool changing and tilting moment on the tool chain.
“Finish machining a large aluminum housing with multiple bores up to 350 mm and IT7 tolerance grade is a demanding application,” said Werner Penkert, Manager Product Engineering. “To machine these large bores with such tight tolerances we need very rigid tools which typically means heavy weight. When manufactured using conventional methods a typical tooling solution for this type of application could weigh as much as 25 kg, too heavy for the existing machines or for an operator working with the tool.”
Intrigued by how Kennametal leveraged 3D printing to produce a lighter-weight stator bore tool for electric vehicle machining, the Voith team turned to the industrial technology leader to collaborate on a solution.
"Kennametal's innovative approach with 3D printing excited and inspired us to take this path together," says Friedrich Oberländer, Director Production Technology at Voith.
The solution: Kennametal expertise in generative design and 3D printing
As with the stator bore tool, Kennametal leveraged its expertise in metal additive manufacturing—plus the concept of generative design—to meet the demanding requirements of Voith’s transmission tool.
With conventional subtractive manufacturing, weight is reduced by removing excess material. But with 3D printing, manufacturers can start with nothing and put material only where it is needed, resulting in lighter-weight, more complex geometries not possible via conventional manufacturing processes.
To fully leverage the design freedom of additive, Kennametal used generative design—an iterative process that optimizes the design of 3D printed parts to meet an application specific set of constraints. The generative design process often results in complex, organic shapes reminiscent of structures found in nature.
In the case of the Voith tool, generative design directly addressed machining forces on the tool, enabling Kennametal to design a solution optimized for stability, stiffness, balancing and coolant supply—with a weight of just 11.5 kg.
Kennametal applied its expertise not only in additive manufacturing but also in machining to produce the tool. The tool pockets are precision machined and designed to be used in combination with Kennametal’s proven RIQ inserts technology.
“Additive is one tool in our toolbox, but we also applied our deep expertise in precision machining to develop a novel solution that efficiently addresses the challenges of boring deep holes in conjunction with multiple large diameters,“ Penkert.
The Results: 50% reduction in machining time
Working in close collaboration with Voith, Kennametal manufactured a prototype tool and put it to the test in its demonstration center in Fürth, Germany—part of a global network of test and demonstration centers where the company works with customers to design, iterate and validate machining solutions.
This solution was particularly challenging to achieve both manufacturing and part quality requirements. Design simulation, additive manufacturing, and practical tests in the demonstration center allowed the team to validate the machining results. Voith then conducted first tests on-site, followed by longer-term tests in series production. Further customer requirements were implemented, and the tool was jointly perfected and finalized.
“The Kennametal tool delivered outstanding quality and performance from the first use, achieving a 50% reduction in machining time, while still meeting accuracy and surface finish requirements. Additionally, the reduced weight limits the load on the magazine, tool changer and spindle—effectively reducing maintenance costs, “ said Oberländer. “Our collaboration with Kennametal clearly shows the enormous innovation potential of additive manufacturing when applied in such cooperative partnership.”
Sand capacity of 130 tons per hour
The SAVELLI Sand-Cooler Type SK 120 comprises a sand capacity of 130 tons per hour (year 2000). The molding line is 850X740X (270/270) mm, 180 mph (year 2014). The molding system enables Formimpress high pressure double squeezing and model side compaction.
13 Sand Coolers sold in the last months
During the last 18 months, SAVELLI installed and sold 13 Sand Cooler Type SK from size 45 to 350. One SK 200 was sold in Italy; 5 SK 180 were sold to Mexico (2), Poland (2) and Italy (1); 3 SK 150 were sold to Italy (1), Japan (1) and Turkey (1). 3 SK 120 were delivered to Italy (2) and Mexico (1). 1 SK 90 was sold to Bosnia and Herzegovina. The SAVELLI company highly welcomes this development and expects further sales in the coming months.
ANKIROS/TURKCAST was last held in 2022 and posted a 2.7% increase in exhibitors (1,048), 8% more net exhibition space (23,582 sqm) and a 9.2% increase in visitors (18,786). This year’s ALUEXPO recorded 15.8% more exhibiting companies (403), a 37.8% increase in net exhibition space (15,191 sqm) and a 12.8% increase in visitors (12,401).
Reclamation of used sand instead of landfilling
Is the reclamation of used sand a real alternative to landfilling? Many foundries have to ask themselves this question. In case of suitability for reclamation, individual concept planning in cooperation with the process supplier and an economic analysis for the overall investment, reclamation can be a real alternative. For this, a sustainable cost reduction must be guaranteed. Other effects, such as the conservation of natural resources and the improved CO2 balance of the plant, also contribute to increased sustainability and should be taken into account in the decision-making process for investment approval. Reclamation must already today be included in the strategy for securing the long-term future of our foundries in Europe. With its own reclamation process and technical center, HWS offers a full service to successfully address this issue.
About Gefond:
Founded in 1994, the company represents leading suppliers in the die casting sector and distributes technologically advanced systems for light metal foundries, mainly serving the automotive industry.
In 2016, Tiziana Tronci, daughter of owner and founder Pierluigi Tronci, actively joined the company after closely following the family business, holding the role of board member and head of new product development after a long international experience in communication and marketing in other sectors.
In 2018, the development of Perpetuo predictive maintenance software began, developed by Gefond in collaboration with T4SM - Tools for Smart Minds, a leader in the creation of predictive maintenance algorithms in other industrial sectors for over 20 years
In 2020, the company acquired Greenbox's patent and know-how for temperature control units and started its own production with Gefond's HPDC to be closer and more flexible to customer needs.
Gefond's challenge is to keep pace with change by trying to anticipate it, supporting trends in the manufacturing industry with innovative technical solutions, with a focus on digitalization and sustainability. Expand the range of services; drive training to increase productivity. Gefond's strategic vision is embodied in five business units: Gefond Products, Gefond Software, Gefond Technology, Gefond Accademia, Gefond Service.
The award honours a future component of outstanding casting quality that requires no machining, is burr-free and has a dark-walled design. A complex component that has high demouldability requirements. In addition, very tight tolerances must be adhered to for large quantities in order to ensure consistent quality. A component that impresses in all respects thanks to the technical casting challenges.
Magnesium: Place 2
The award for the cylinder head cover is a well-deserved recognition of its outstanding properties and casting challenges, especially when it comes to ensuring pressure tightness with a low wall thickness. In addition, the high surface requirement is another important aspect that was taken into account in the award. A flawless surface is of great importance to ensure optimum performance and aesthetics. Profitability is given by manufacturing advantages with 30% weight savings even for die casting in small series, with an additional investment saving through a uniform casting blank for two mirror-symmetrical finished parts.
Magnesium: Place 3
The award honours a component that embodies the key advantages of Mg die casting, such as low weight. With four slides per cavity and two cavities, the moulding technology used is impressive. Mastering the long flow paths and good thermal management of the mould require knowledge and precision. In addition, resource-saving moulding by means of reduced quantity spraying is used. The component is particularly characterised by high surface requirements and high strength combined with high ductility.
Zinc: Place 1
This is a sanitary component for a high-quality and exclusive shower system. With a length of approx. 60 cm and a weight of 1.3 kg, it is a large component with particularly high demands on the surface and dimensional stability.
Zinc: Place 2
The prize was awarded to an electronics housing for mining, which is a substitution of a steel construction with a weight of 4.13 kg and thus a 50 % weight saving. The development of a new market sector with high demands on explosion and corrosion protection as well as tight tolerances, particularly in the area of the 12 connector sockets, also characterise this component.
Zinc: Place 3
The award honours a component of outstanding casting quality combined with compliance with the highest tolerance requirements. Due to the use of identical internal components, the internal shielding cross is 45 degrees to the main mould division. The requirement for a conductive housing shielded against electromagnetic effects is also recognised.
Aluminium: Place 1
A highly innovative aluminium structural casting with a wall thickness of just 1.5 mm was honoured. The special feature is the production using 4-plate technology with considerable advantages in terms of flow paths and sprue. This means that the sprue areas can be produced in high quality. In addition, the aluminium lightweight construction has been able to reduce the CO2 footprint by 75% by replacing magnesium with aluminium.
Aluminium: Place 2
The casted e-coil for wheel hub motors is a completely new component application and manufacturing method. The coils made of rotor aluminium produced using the die-casting process have a 50% reduction in component weight and almost comparable performance data as well as better heat dissipation of the aluminium coils with a simultaneous 60% reduction in material costs compared to wound copper coils. Lower processing temperatures significantly reduce the CO2 footprint during production compared to copper coils.
Aluminium: Place 3
The prize was awarded to a component in which a die-cast component with cavities was successfully produced using the die-casting process with the recycled alloy AlSi9Cu3. The salt core technology already used in many development projects could be realised here in large-scale production using two composite salt cores to reproduce the water channels. This enabled both weight and costs to be saved compared to the chill casting variant.
With its seed investment in the start-up, the Foundation is taking risk and thus providing the financial basis for the development of production capacities in Germany and the worldwide use of the technology.
"Financial/y, the patent portfolio may be va/ued at a significant doub/e-digit million amount, but we va/ue the positive impact of CASTCOIL many times higher." Denise Ulbrich elaborates on the Foundation's involvement.
About the Bienenelfe Foundation
The smallest bird in the world (a hummingbird called "bee elf") symbolizes the great change that the Foundation can achieve, contributing on small scale. Regionally rooted, ecologically and economically sustainable -the Bienenelfe Foundation proves that animal and nature conservation is possible far away from radical ideologies. Not to treat living beings as an industrial product in the sense of a rational cost/benefit analysis, not to want to prescribe animal and environmental protection as a doctrine, but to bring about a great motivation to participate on a small scale through heart and mind - that is the mission statement of the Bienenelfe Foundation.
About Castol
Cast Coil GmbH, headquartered in Muenster, Germany, has secured the exclusive rights to use and market Fraunhofer's CASTCOIL technology. With a team of scientists and practitioners, the company enables licensees to produce CASTCOILs in high quantities and quality and at the same time imparts the know-how about the use and possibilities of new geometries and materials to the manufacturers of electric motors and generators
Source: www.castcoil.de
Sandy Munro travelled from the USA to share his experiences in the field of product development with the participants in a passionate and striking manner. Of course, the focus was on the advantages of giga-casting and aluminum for e-mobility, and Munro believes that much is still possible and that the hype for large structural components in die casting is only the beginning.
In the selection of topics, the organizers always succeed in blending a successful mix of general statements, specialist lectures from the foundry environment and product presentations by FSA members into an interesting whole.
The exchange of knowledge, insights and experiences has become synonymous with Villa Baiana and is to be continued. Great changes are coming, IDRA head Riccardo Ferrario is sure, we just have to be prepared. The future opens opportunities, and the organizers are sure that with the support and participation of their partners, they will be able to shape them in an innovative and sustainable way.
The organizers’ thanks are rightly directed at the commitment of the participants, who are an integral part and contribute significantly to the success. Add to this the charm of the location in Franciacorta, the proximity to IDRA's headquarters with the possibility of allowing sufficient exhibition space for all FSA members and the great hospitality.
About Foundry Star Alliance
The Foundry Star Alliance is a group of leaders in their specific field of activity who have decided to work together and combine their efforts to best support the rapid growth of the global HPDC light alloy markets. The global approach of the OEMs requires a level of knowledge and skills that is not available in a single company. FSA members work together and pool their collective resources and specific technologies, resulting in the best integrated, automated and reliable high pressure die casting production core on the market.
IDRA – STØTEK – KMA – MECCANICA PI.ERRE – IECI – COSTAMP – FONDAREX – WOLLIN
Melt treatment
In recent years, we have added a number of features and technologies to our FDU and MTS automated aluminium melt treatment technologies. These advances provide foundries the opportunity to gain new perspective on and control of their treatment process.
Our SMARTT degassing software offers various programs for rotary degassing; the operator must simply define a target melt quality. Based on ambient conditions, melt temperature, rotor design, and alloy composition, the software then calculates the best treatment practice to achieve that goal. Optimisation modes are also available to reduce inert gas consumption, minimise degasser wear, or provide fastest degassing and treatment speed. Treatment parameters are automatically relayed to the FDU MTS equipment, while a customised report system records all parameters.
Low Pressure vs. Counter Pressure – a real-life example
Depending on the application we have already replaced 12 counter pressure casting machines with 8 low pressure casting machines.
Sounds interesting? We think so too!
Register for this webinar here:
OEMs master the know-how of integrated die casting through independent research and development
After Tesla Model Y adopted the integrated die casting process for the first time, a new wave of integrated die casting has staged worldwide. A complete industrial chain layout has been formed between upstream die casting machine manufacturers, material manufacturers and mold manufacturers, as well as midstream die-casting companies and downstream automakers.
There are currently two main business modes:
Independent research and development of OEMs: OEMs: directly purchase die casting machines, molds and materials, and then build their own factories to produce die casting parts. Tesla, Xpeng and Volvo adopt this mode.
Procurement: OEMs directly purchase die casting parts from die-casting manufacturers who buy relevant materials to produce die casting parts and deliver them to OEMs. HiPhi, NIO and Li Auto follow this mode.
What do hydropower and casting technology have in common? Both are industries with a long tradition of having great forces at work. They are also considered to be conservative and often underestimated when it comes to topics such as digital transformation. But this is not the case. VERBUND, for example, operator of Austria’s major hydropower plants, has been digitally safeguarding the operational readiness of its plants for years.
For this purpose, real sensors feed the digital images of critical components with real load data. Virtual sensors at critical points allow the evaluation of the occurring load and the assessment of wear. If defined limit values are reached that signal a failure, technicians can quickly take care of maintenance or replacement without complications.
Many are still talking about “digital twins” – VERBUND has already implemented them together with its partners ITficient and CADFEM.
Another link to casting technology was created in 2019 at the CADFEM Conference in Linz. The presentation of the VERBUND project impressed Florian Sipek (physicist at RAUCH FT, the Austrian specialist for melting technology) so much that he transferred this knowledge to his own products and also inspired his colleagues with this idea. However, this is not surprising, since innovation and the courage to explore new paths are part of the DNA of RAUCH FT. These qualities have contributed to the highly specialized company becoming the world leader in melting technology. The company takes pride in being considered the world market leader for Mg melting systems.
Florian Sipek
Head of R&D, RAUCH Furnace Technology
In recent years, new alloys have been developed for structural casting that do not require any subsequent heat treatment. This saves time, money, energy and equipment.
However, this also means that the release agent residues on the surface of the castings are no longer thermally decomposed! In most cases, for structural parts without heat treatment special release agents must be used, which can then be easily removed from the castings.
Geiger + Co. Schmierstoff-Chemie GmbH developed the polysiloxane-free Trennex CI 7 for this application years ago together with a well-known OEM and successfully launched it on the market. Trennex CI 7 therefore has an OEM approval for naturally hard alloys without heat treatment, which are then bonded. Trennex CI 7 does not contain any polysiloxanes or ingredients that are difficult to wash off. As a result, even with unwashed raw parts, the surface tension required for coating and painting is significantly higher than with conventional release agents:
The successful position in the Global Market can be explained by the fact that SAVELLI was able to react, analyse and interpret on time through a strategy of "re-shoring" and "friend-shoring" of important multinational groups which are investing in Mexico, Poland, Germany, Bosnia, Turkey and in UK. International players such as Brembo, MAT Foundry Group, Fritz Winter Eisengießerei, Castings PLC-William Lee, PMP Industries and Elginkan-Odöksan have chosen SAVELLI and its technologies for the development of new Green and Brown-field foundry projects. This, in response the loss of the important Russian market which was worth 50% of the turnover (from € 21.3 million in 2021 to € 10.6 million in 2022).
Despite the European Parliament's push for the electrification of mobility, to the detriment of the internal combustion engine, the automotive industry remains the main one for SAVELLI. The production of high-volume cast-iron products like brake discs, drums, chassis bracketry etc… for passenger cars and trucks is unlikely to decrease in like the production of large engine blocks and cylinder heads for heavy vehicles. Considering the current orders, SAVELLI remains focused on automotive projects, especially projects related to the production of heavy transport, agricultural and earthmoving vehicles.
In recent years, with the preference of global capital for investment in Southeast Asia, we have seized opportunities to continuously consolidate and improve its core competitiveness and brand influence, attracting a significant number of customers and partners.
Singapore is an essential part of YIZUMI's global value chain. We have steadily and actively expanded local multinational enterprises with the local agent Nah Industries in industries such as packaging, 3C electronics, home appliances, and so on.
In the future, we will continue to expand the local market, and strengthen our partnership with the local agent to actively respond to the needs of the local and neighboring markets with high-quality and high-performance products, as well as prompt and thoughtful service support, propelling our expansion in the Southeast Asian market.
About SPETA
SPETA was founded in 1982 and has a history of over forty years. It is a leading industry association in Singapore that serves and promotes the employment of advanced manufacturing technologies and Industry 4.0 in the precision engineering industry, with the goal of becoming a professional and prestigious industry association. It now has over 300 active members, including local registered SMEs, MNCs, manufacturers and distributors engaging in precision engineering components, products, tools, equipment, and machinery, as well as companies that support and service industries such as aerospace, automotive, healthcare, and semiconductors.
2. Spreading the Word:
In our sustainability area, we're introducing interactive activities to raise awareness about this crucial topic. This includes virtual foundry solutions tours tailored to different approaches in foundries and die casters, along with a quiz designed to test visitors' knowledge and unveil surprising statistics!
3. Encouraging Action:
We'll provide information at Euroguss about our commitment to our Science Based Targets Initiative. Our experts will be available to discuss the involved processes and how we can assist your foundry in meeting these targets. Representatives from Strikowestrofen, DISA, ItalpresseGauss, and Monitizer will also be present, offering tailored solutions to achieve your specific goals—whether it's reducing gas consumption or addressing scrap issues.
We eagerly anticipate your presence at Euroguss and look forward to collectively taking action and leading the way towards a more sustainable future.
Come visit us at Euroguss 2024: Hall 7, Stand 7-278
In addition, the release agent supply system can be equipped with a supply of concentrated release agent for minimum quantity spraying or demoulding oil. The size of the buffer tank is designed according to the expected maximum consumption. The quantity of release agent mixture in these containers is adjustable. This allows the quantity stored to be adapted to the actual consumption, which ensures continuous renewal of the release agent mixture. For release agents that segregate quickly, an electric agitator can be used to maintain the mixture permanently or intermittently.
To further reduce the maintenance effort, decentralized release agent supply systems can be equipped with an automatic flushing function. This allows not only the system to be flushed but also the entire line connection up to the spray head at the end of production or when production is interrupted. Various cleaning agents and hot water from a separate tank are usable for this purpose.
Visit Gerlieva Sprühtechnik GmbH at EUROGUSS 2024 in Hall 7 | Booth 7-234
So-called giga/megacastings are just one way to make production for vehicles easier and there are many other development opportunities.
The interview gives an appetite for deeper insights and, above all, for the exchange during EUROGUSS in Nuremberg.
Riccardo Ferrario invites you to visit the Italian companies and listen to the full interview in the FP podcast in advance: For the full List, please click here
Visit AMAFOND at Hall 9 / Booth 9-329
Fink & Partner, with its [FP]-LIMS solution, has made a name for itself as a reliable and established partner in the foundry industry. For decades, many foundries worldwide have relied on this LIMS to optimize their processes and ensure product quality. [FP]-LIMS is characterized by its adaptability and user-friendliness, which enables foundries to manage their data efficiently and carry out precise analyses. This long-standing market presence and the trust that foundries worldwide place in [FP]-LIMS underline the reliability and effectiveness of the solution.
During this time, CAEF has achieved several milestones, such as intensifing the including fostering collaboration between members, advocating for the industry's interests on the European stage, and promoting sustainability within the sector towards member associations, foundries and policy-makers.
The largest projects in his office was the redevelopment of the governance structure (bye-laws) and reframing of CAEF mission as well as strategy. While bidding farewell to Mr Lohe, the Board is confident in the resilience and strength of CAEF. The association will embark on a thorough and transparent search for a new Secretary General to carry forward the legacy of leadership and continue the vital work of promoting the interests of the European foundry industry.
The association’s president Chiara Danieli expresses her gratitude on behalf of CAEF to its members, partners, and stakeholders for their continued support for Mr Lohe and the General Secretariat. Regular updates on the recruitment process for the new Secretary General will be provided to ensure transparency and engagement.
Background information on CAEF:
CAEF is the umbrella organisation of the national European foundry associations. The organisation, founded in 1953, has 22 European member states and works to promote the economical, technical, legal and social interests of the European foundry industry. At the same time, CAEF implements activities which aim at developing national foundry industries and co-ordinating their shared international interests. The General Secretariat is situated in Düsseldorf since 1997.
CAEF represents 4 400 European foundries. Nearly 260 000 employees are generating a turnover of 39 billion Euro. European foundries are recruiting 20 000 workers and engineers per year. The main customer industries are e.g. the automotive, the general engineering and the building industries as well as the electrical engineering industry. No industrial sector exists without using casted components.
Further information at www.caef.eu.
Metal Power has established itself as an innovator and trusted supplier of Optical Emission Spectrometers (OES) for metal analysis in the foundry industry over the past two decades. These instruments are known for their precise and fast analysis of metal samples. The high accuracy and reliability of these devices contribute significantly to quality assurance in production. Metal Power has consistently focused on products built with the latest technology and optical, analytical, and design innovations, enabling foundries to take their material analysis to a higher level of accuracy, precision and efficiency.
Joint strengthening of the foundry industry
The combination of [FP]-LIMS and Metal Power's OES instruments creates a powerful solution for metal analysis. The partnership enables more precise control of metal composition - an essential criterion for ensuring product quality and optimizing production processes in foundries. With this innovative combination of software and hardware, Fink & Partner and Metal Power are setting new standards in quality assurance and increasing efficiency in the foundry industry.
Deep customization and “heavy-duty” manufacturing of moulding lines and sand plants stay at the base of SAVELLI sales policy and business development. SAVELLI is a "boutique company" of 45 high skilled people, for which quality and customer care is the main priority. Its mission is to develop the best technological solutions for the Cast Metal Industry, mainly for the foundries which operate with the “Green Sand” Moulding Process, which is still the most convenient and cost-effective system to produce high volumes of quality castings.
The company’s philosophy is "Green" and based on environmental protection, and this is evident from how SAVELLI produce the energy consumed every day through a photovoltaic system located on the roof of its headquarters as well as how SAVELLI automates its products with low energy consumption and energy recovery solutions.
Granulated fluxes can be added through the automated MTS and provide many advantages, such as improved melt fluidity during casting, reduced inclusions, and improved mechanical properties. Our new range of granulated fluxes includes COVERAL, SIMODAL, and NUCLEANT fluxes, which cover the principal foundry operations of cleaning, drossing, modification, and grain refinement. They have been specially formulated for use in conjunction with FDU and MTS to keep smoke and fume to a minimum.
In the webinar you get a short process overview but more importantly information and insights you have not heard before!
Meet the Expert during Euroguss 2024!
We warmly invite you to meet our Low Pressure Casting experts in personal and deepen conversation about the webinar content at EUROGUSS 2024 in Nürnberg!
Visit us in hall 7A, booth 650 from January 16 to 18, 2024.
Check out the video about Kurtz Automated Low Pressure Foundry:
In the long run, automotive integrated die casting will gradually return to the procurement mode. OEMs have to invest heavily in building their own production lines, and they may be extremely concerned about the later operation and management. Tesla, the representative of the independent R&D mode, has cooperated with die casting manufacturers in order to add new capacity by outsourcing in the future. The main purpose of the OEM's self-research is to master the know-how of integrated die-casting, which is convenient for technical communication with suppliers in the future.
Upstream: Super-large die casting machines debuted, helping vehicle-level integrated die casting
Large die casting machines are the key to realizing automotive integrated die casting. At present, integrated die casting requires 6000T (or above) die casting machines. Globally, IDRA (a wholly-owned subsidiary of L.K. Technology), Bühler Group, as well as China-based L.K. Technology, Haitian Die Casting and Guangdong Yizumi can produce die casting machines over 6000T.
Even in a sector as rich in tradition as the casting industry, we are using the digital twin to drive digitalization forward, and we are reaping the Benefits.
ABOUT RAUCH FT
RAUCH FT stands for high-quality melting technology solutions for magnesium, zinc and non-ferrous metals that integrate perfectly into individual production processes. Know-how from research and experience in the implementation of complex systems ensures sustainability and reliability over several production cycles. The RAUCH FT team is characterized by the highest quality standards and absolute cost awareness, as well as the trusting, long-standing relationship with its business partners. www.rauch-ft.com
67 employees at the company headquarters in Gmunden, Austria
45 countries worldwide – the sales region of RAUCH FT
2,2 Mio. tons of melting capacity is provided by RAUCH FT products
DIGITALIZATION TO THE EXTREME
Melting furnaces have their work cut out for them. When metals are melted, recycled, and alloyed in these furnaces, the temperature can reach up to 2,000°C, gas flows can reach speeds of 1,000 km/h and load changes are the norm.
Greater reliability of melting systems is extremely valuable for operators. If a system suddenly comes to a standstill, there is not only a risk of damage to the furnace, but also of serious production delays or failures. In the worst case, employees could be put at risk.
The idea: Digital twins should significantly reduce such dangers by identifying problems at an early stage. RAUCH FT strives to provide customers with valuable insights during ongoing opeartion, which includes alerting them to maintenance or cleaning needs.
If a melting furnace suddenly breaks down, the consequential damage for our customers is often serious. The significantly lower risk with our systems is a real competitive advantage.
Hannes Viertbauer, Sales Manager, RAUCH FT
DATA AND SIMULATION KNOWLEDGE PERFECTLY ORCHESTRATED
There are still no comparable approaches in casting technology. RAUCH FT, together with ITficient and CADFEM, has tackled the challenge head on, just as the trendsetters at VERBUND did. ITficient for data management, business model and IT architecture; CADFEM for all simulation, from flow to various transient and nonlinear structural mechanics applications and sensitivity studies to system simulations including condition monitoring.
RAUCH FT was well prepared for the digital twin. Many systems and components are already being simulated. The majority of these simulations deal with fluid mechanics. The spectrum ranges from transient cooling and heating processes to processes in dosing or flow pumps to chemical reactions.
In addition to a powerful IT infrastructure, there is already a large data pool available for the system via remote maintenance. The evaluation of this data provides valuable insights into the operation of the furnaces, which are also incorporated into the digital twin.
Teresa Alberts
ITficient AG
WIDE RANGE OF APPLICATIONS
In recent years, Trennex CI 7 has found various applications in structural parts and other thin-walled castings that are supposed to be suitable for subsequent bonding or coating:
» Trennex CI7 is diluted with water between 1:50 and 1: 150 depending on the application.
» The future use of Minimum Quantity Spraying or Hybrid Spraying was also taken into account during development.
» For optimum results with Minimum Quantity Spraying, we recommend our further development, Trennex CI7 B, based on our Trennex CI7.
Visit Trennex at EUROGUSS 2024 at Hall 7 / Booth 7-114
Speakers at the 2nd International FSA Forum:
Automotive News
Luca Ciferri
How future CO2 regulations will influence powertrain choices around the world
Munroe & Associates
Sandy Munro
The Die is Cast
Raffmetall S.P.A.
Ruggero Zambelli
New generation of premium recycling Aluminum alloys
Gnutti Carlo Group
Eric Müller
Connectivity @ Saltcore-technology towards sustainability
Stotek A/S
Hans Henrik Würtz
Future molten metal system for zero emission foundries
KMA GmbH
Christian Kurtsiefer
New solutions for heat recovery and exhaust air purification at melting furnaces
FSA
John Stokes
GIGA Tech – What`s next?
Brembo S.P.A.
Roberto Vavassori
Light…Years ahead
Arcelormittal S.A.
Jérome Favero
Steel E motive
Voestalpine AG
Karl Radlmayr
Different material usage
Magna Group
Bastian Drees
Structural application and foundry challenges
Costamp Group S.P.A.
Andreas Kant
Giga Tools challenges and opportunities
Fondarex S.A.
Dominik Baumgartner
Vacuum and jet cooling for Giga Castings
IDRA S.R.L.
John Stokes
New Thixo process
Bocar Germany
Jochen Merz
Bocar to remain a reliable Partner
IECI S.R.L.
Fderico Di Giovanni
Thermal Control for Giga Castings
Wollin GmbH
Björn Wollin
Die spraying challenges
Meccanica Pi.Erre SRL
Federica Pederzoli
Trimming and cutting operations
Vistit Idra S.r.l at EUROGUSS 2024 in Hall 7 / Booth 7-612
Crucibles
We continuously improve our crucible technology to provide solutions that reduce energy consumption, increase output, and improve production efficiency. Recent innovations on display at EUROGUSS 2024 will include:
- ENERTEK ISO crucibles, which utilise a highly-insulating, proprietary Vesuvius coating to significantly reduce heat loss and decrease energy use in induction melting or continuous casting applications.
- DURATEK crucibles, designed to provide extended life, especially in highly-corrosive conditions. The latest DURATEK SUPERMELT crucibles possess superior fracture toughness, high temperature strength, and oxidation resistance to ensure long life in aggressive aluminium melting operations.
Higher-tonnage die casting machines can facilitate breakthroughs in die casting size and structure. Now, Tesla, L.K. Technology, Guangdong Hongtu, Haitian Die Casting and other companies have started research and development of die casting machines above 12,000T. In September 2022, L.K. Technology and Guangdong Hongtu successfully released a 12,000T super-large intelligent die casting unit jointly, marking the advent of world's highest-tonnage die casting machine. This is expected to boost vehicle-level integrated die-casting.
Midstream: Die casting leaders emerged
As midstream die-casting companies, Wencan Group, Tuopu Group, Guangdong Hongtu, Xusheng Auto Technology, Millison, etc., have deployed automotive integrated die casting by purchasing large die casting equipment and cooperating with automakers.
The implementation of digital twins is independent of an industry. It is based on data, physics and the customer's product knowledge.
HOW LONG WILL THE CRUCIBLE LAST?
The ideal component for the first practical implementation is the crucible. The welded steel construction is highly loaded. As Florian Sipek explains, “2000°C hot flue gas on the outside, corrosive protective gas, and hydrostatic pressure of up to 4t melt on the inside. You also have extreme temperature gradients, the radiative power of the flame and high velocities with inhomogenously distributed radiant energy”.
If the crucible fails, the system comes to a standstill. Maintenance is usually based on experiential values, which, in an ideal world, can be beneficial. But as soon as irregularities occur in the processes or during handling, there is a risk of failure and thus consequential damage. “This is precisely when the value of predictive maintenance becomes apparent,” summarizes Florian Sipek.
Christian Abramowski
Technical Manager Hanover, CADFEM Germany GmbH, Hanover
Digital twins are an important symbiotic extension of reality through simulation.
Innovative sand core binder solution for HPDC
A key limitation of the high pressure die casting process (HPDC) is the inability to produce complex, hollow castings, at high volume, and in a cost-effective and sustainable way. This is due to the difficulty in producing suitable cores. Standard sand cores cannot be used, as they are difficult to remove after casting and do not provide adequate surface finish. Salt cores are more suitable, but are expensive to produce and present other operational limitations.
In response to this challenge, we have developed the WASCO water-soluble binder and coating, which we will showcase at EUROGUSS 2024. This innovative binder system demonstrates high bending strength and has been used successfully in both liquid and semi-solid HPDC processes, even in severe conditions. With the use of an appropriate coating, WASCO-based sand cores can exceed 1000N/cm² and are thermally resistant up to 750°C. Post-casting removal is achieved simply by flushing with water, preventing any risk of damage or crack initiation.
Currently, Wencan Group, Tuopu Group and Guangdong Hongtu have first-mover advantages in experience accumulation and order intake. All three have established cooperation with automakers and successfully completed the trial production of integrated die casting parts. Especially, Guangdong Hongtu is superior to others thanks to its heat-treatment-free aluminum alloy patent and the yield rate of 85%-90%. So far, it has not only obtained the designation from Xpeng, but also become Tesla's only die casting partner in integrated die casting.
Downstream: Automakers scramble to deploy integrated die casting in a bid to integrate the upper and lower car body
At present, Tesla, NIO, Xpeng, HiPhi, Volvo, Great Wall and other automakers have made layout in the field of automotive integrated die casting.
In terms of emerging automakers, Tesla has officially delivered Model Y with integrated die casting floors. NIO ET5 with an integrated die casting rear subframe is about to be delivered. In addition, Xpeng, Li Auto and HiPhi have put integrated die casting on the agenda, and they may apply it to vehicles in 2023.
As for traditional automakers, Volkswagen and Volvo have a long-term timetable for the layout of integrated die casting, and they expect to achieve mass production around 2025. Chinese automakers Changan and Great Wall have started bidding for integrated die casting projects, and they are likely to accomplish mass production in the next two to three years.
EXAMPLE: INFLUENCES OF SEGREGATION
The idea of digital condition monitoring of the crucible is an interplay of real measured values and virtual sensor technology. Due to the segregation that occurs in the melt (i.e., the deposition of certain compounds), a sludge forms at the bottom of the crucible. This leads locally to a change in the flow conditions and the material parameters of heat conduction and heat capacity, which disturbs the heat transfer at the bottom of the crucible from the furnace chamber to the melt. In connection with the inhomogeneous temperature distribution on the outer wall, high stresses arise in the crucible.
The sludge volume is therefore an important boundary condition for a correct prediction of the real-time load on the crucible as well as for the reliability of predictive maintenance. Due to the environmental conditions in the crucible and in the furnace, the use of real sensor technology for temperature measurement is hardly possible. Therefore, CADFEM's concept provided virtual sensors for the simulations. Together with a sump quantity calculated from the temperatures and the process parameters, a local load on the crucible can thus be concluded with only a few measuring points and input variables.
Precise modeling of the temperature distribution in the furnace chamber by computational fluid mechanics (CFD) and of the stresses at the weld seams (structural mechanics, FEM) are essential for predicting the remaining life cycle of the crucible. On the CFD side, a combustion simulation of the burner and the furnace chamber is performed for a correct prediction of the flame temperature, the heat radiation, and the momentum input. Based on the CFD results, a temperature field and a stress analysis are performed using the melt as a variable heat sink to represent the melting of ingots thrown in.
Now, major OEMs mainly apply integrated die casting to the rear floor, the front cockpit, etc. With the advent of higher-tonnage die casting machines, integrated die casting is expected to spread to lower body assembly, upper body integrated casting parts, and even body-in-white in the future.
Tesla plans to replace the 370-part lower body assembly with 2-3 large die casting parts. Tesla has extended the integrated die casting to the front and rear floors. At the same time, the upper cover of the battery pack and the middle floor of the vehicle are combined into one for integrated die casting, which can reduce the vehicle weight by 10% and increase the cruising range by 14%.
IN EVERY INFRASTRUCTURE
The digital twin must be adapted to the individual requirements of the end customer – both in terms of the processes to be modeled as well as the IT infrastructure to be used. A concept for IT integration is an important building block in the implementation, including the handling of sensor data, the operation of the twin, security and network issues. ITficient was able to build on a data pool and an IoT platform at RAUCH FT.
The necessary microservices – receipt of sensor and machine data, calculation of virtual sensors, models and processes, data storage and evaluation, and visualization of results – were integrated in such a way that IT resources were optimally utilized, no isolated solutions were created, and RAUCH FT retained full control over all processes in its hands, meaning that it could also develop them further independently.
Source: http://www.researchinchina.com/
ITFICIENT AND CADFEM
A powerful digital twin has two essential layers: Accurate simulations and a reliable IT infrastructure. The project will be successful if both sides mesh with each other. RAUCH-FT was able to achieve this because CADFEM and ITficient, two partners with a great deal of experience in their respective fields, were involved. At the same time, they are in close and trusting exchange, as they are both closely linked organizationally as companies of the CADFEM Group.
The third member of the group is RAUCH FT, supported by its pilot customer Georg Fischer Casting Solutions. With the digitally monitored melting furnace, RAUCH FT achieves more occupational safety for its employees. In-depth product knowledge, openness to new things, strong communication, a clear idea of what was to be achieved and the participation of all departments in the project were the keys to success. Existing competences were integrated. Some tasks were carried out cooperatively, others as a pure service by CADFEM or ITficient - always in the sense of the defined goal of a complete know-how transfer to RAUCH FT.
The crucible was only the starting point. RAUCH FT intends to scale the acquired skills for planning, construction and management of a digital twin and in the future provide all relevant components such as metering pumps, heating systems or circulating pumps and entire systems with digital solutions for predictive maintenance, thus setting standards for casting technology and customers like Georg Fischer.
About ITficient:
ITficient, a CADFEM Group company, supports companies on their journey to digital solutions such as predictive maintenance through Digital Twins. From onboarding to implementation and scaling, it's about working with customers to find and follow the best path to their digitalization goals. www.itficient.com
Both occupational safety and effort are improved by the digital twin. This makes GF casting solutions attractive as an employer, especially in times of increased staff shortage.
Andreas Thaler, Head of Operating Technology GF Casting Solutions Altenmarkt
This vision does not end with our own products. A classic die casting cell not only consists of the melting furnace, but also of other components from various manufacturers. Be it robots, presses, heating/cooling units or the die casting machine itself, almost every component in the foundry has the potential for a digital twin.
A start has been made: By RAUCH Furnace Technology (FT).
A DIGITAL TWIN NEEDS LOVE ... TO THE DETAILS
Stakeholders: Who in the company is affected?
Perspectives: What are the challenges, what are the added values?
Personas: Who are the future active users?
Prioritization: Which use case is suitable to start with?
Technical analysis: Which models, sensor data, IT infrastructures are available?
Recommendation: A moderated intensive workshop with in-depth analysis of requirements, goals and prerequisites has proven to be the basis for a successful Digital Twin project. This is followed by a rough concept of the use case, detailed proof of concept, implementation, and scaling to other use cases. workshop(at)itficient.com
Visit RAUCH Furnace Technology GmbH at EUROGUSS 2024 at Hall 9 / Booth 9-617
What does this mean from a metallurgical point of view? Iron melted in the cupola has a high sulfur content due to the process. For the production of spheroidal graphite cast iron, therefore, single- or two-stage processes are used to produce the ready-to-cast melt. However, the production of vermicular graphite is consistently based on two-stage processes. In these two-stage processes, the first stage is used for desulfurization, typically achieving sulfur levels of 0.06 to 0.025%. In the second stage, the morphology of the graphite phase and the composition of the metallic matrix are then adjusted to achieve the desired mechanical and physical properties of the material in the component (Fig. 2).
When this is achieved: automatic evaluation with cost rates = calculation (= “cost to cast” / “C2C”) the FRP®.DTG can, with only a few inputs, generate your complete casting part with all materials and operations (=digital twin) in a structured way up to the calculation (cost to cast). Use the FRP®.DTG to optimize your work preparation, to protect the company know-how and establish a connection between your design and development (CAD / CAE) with the corporate level (ERP/FRP®).
Heunisch sales manager Thomas Laue then led through the varied programme, which included the following presentations:
Impulse lecture Dampfkugel
Dr. Pillkahn, PROASSORT GmbH
Development on the energy market
Dr. Schimansky, BDGuss
German foundry industry
Mr. Gerhäuser, Heunisch GmbH
Decarbonisation
Mr. Eckl, Heunisch GmbH
Development on the scrap market
Dr. Pillkahn, PROASSORT GmbH
Panel discussion
The energy transition from the perspective of industry and politics
Participants:
Barbara Fuchs (Greens), Dr. Christian Schimansky (BDGUSS), Carsten Träger (SPD), Kai Kowalewsky (Bitzer), Tobias Winkler (CSU) and Dr. Christiane Heunisch-Grotz
There was no question that there was enough material for discussion and enabled the participants to have a broad spectrum of views. In particular, Dr. Christian Schimansky, as a participant of BDGuss, focused on the concerns of German foundries and called for a legally regulated bridge electricity price for the energy-intensive foundry industry. In the exciting panel discussion with state and federal politicians, he also pointed out glaring competitive disadvantages for German foundries, such as the excessive bureaucracy.
Customer representative Kai Kowalewsky (Bitzer Kältetechnik) confirmed that potential foundry customers naturally look around the world market, although they greatly appreciate the quality and reliability of German companies. In line with the industry, the entrepreneur added clearly to politicians in the panel discussion: "The way Germany is behaving economically at the moment is frightening".
It was only good that the event, which was characterised by Franconian hospitality, also had plenty of glimmers of hope to offer, and after the successful evening event on the next day, the landfill site tour and foundry tour formed a positive conclusion.
About the Heunisch GmbH foundry in Bad Windsheim
At the Bad Windsheim site, Heunisch GmbH produces machine-moulded castings from GJL and GJS.
- Casting weights: from 20 kg to 600 kg
- Series from 500 pieces to 50,000 pieces per year
- Agricultural industry: e.g. the complete drive, axle range
- Air and refrigeration compressor construction: e.g. compressor blocks, bearing covers
- Commercial vehicle industry: e.g. differential housings, gearbox housings
- Drive technology: e.g. cylinder heads, crankcases, wheel housings
- Construction machinery: e.g. vibratory plates, gearbox housings
- Marine technology: e.g. shaft bearing blocks, gearbox housings, thrust bearings
- Valve and hydraulic pump manufacturers: e.g. hydraulic blocks, oil guide housings
The speeches were followed by the "History Talk" discussion, led by Christian Kunz with Marco Schulz, Franz Holl and Alfred Elser. The discussion provided fascinating insights into the company's past, as well as memories of past successes and challenges.
The two-day trade exhibition, which was organised as part of the celebrations, also remains a special memory. This comprehensive two-day programme (https://125jahre-moessner.de/) enabled visitors - including many well-known companies - to discover the world of Mössner, as well as the latest trends and developments. Furthermore, it was an opportunity to make new contacts.
The 125th anniversary celebrations were an unforgettable event for Mössner, with pride of the past and joyful prospects for the company's future.
Continuous desulfurization of cupola iron is possible using compounds containing calcium. Specifically, the use of calcium carbide as a desulfurization agent is also an option, but this is rarely used in foundry processes today due to environmental concerns.
Discontinuous desulfurization processes include the Mg wire feeding process and the modern lime injection process developed by the Institute for Technologies of Metals at the University of Duisburg-Essen under the direction of Rüdiger Deike and the materials development department of the Fritz Winter company under the direction of Marc Walz [3], [4].
To produce the ready-to-cast melt from the resulting base iron, a second step involving treatment with magnesium, rare earths and inoculants is carried out. In particular, the wire feeding and the pour-over method have become established. Modern wire feeding methods also use an inoculation wire in addition to the magnesium wire, resulting in dynamic inoculation during treatment. The final step on the way to the desired metallurgy is inoculation during the casting process. This inoculation can be carried out by means of a pouring jet inoculation or an inoculation in the casting or runner system.
Requirements for a modern induction furnace melting operation
As already described above, a modern induction furnace can only work with high quality metals and scrap. That is why induction furnace manufacturers also usually recommend a certain grade of scrap with which the equipment should be operated. Otherwise, the full output cannot be generated due to the poorer coupling. However, the goal must be a constant power range – ideally with 100% energy input over the course of the batch to minimize the melting time and thus the energy input and, of course, to maximize productivity.
However, the coupling of the induction furnace depends on the load circuit: the power of the equipment adjusts according to the bulk of the feedstock based on its electrical as well as magnetic properties. Stationary losses due to recharging must therefore be optimized. ABP makes it possible to measure and evaluate these operations and to guide the customer in batching. For this purpose, ABP uses the patented OptiCharge tool it has developed itself (Fig. 3). It measures the electrical influencing variables necessary to optimize performance. These parameters are compared to the current weight and the algorithm determines the lowest possible weight necessary to achieve full power consumption. The desired result is controlled batching for optimum adaptation of the weight to the power consumption over the complete batch duration. Whenever physical conditions permit, re-batching can be performed. This cold material couples optimally due to its ferromagnetic properties until it loses them at the Curie temperature point at 760°C.
The technical furnace parameters for this are recorded by the digital inverter control and converted into recommended actions for energy-efficient loading with the OptiCharge system. When starting up a batch with partial filling of ferromagnetic melting material, small portions of this material are automatically refilled. As a result, measurable energy savings and production increases can be achieved in daily production operations as compared to non-controlled batching. Surveys show that induction furnaces already produce less than half the CO2 emissions to melt one ton of cast iron compared to cupolas in today's electricity mix. If the share of electricity generated from renewable sources increases, CO2 emissions decrease accordingly.
This system is therefore eminently important for the transition from the cupola to the induction furnace in order to continue to provide a high continuous supply of the molten iron for the process. This is where OptiCharge reduces power dips to a minimum.
The physical background: The possibility to operate in the constant output range was created by the fact that there are thyristors in different sizes and it has become established that the next larger size is always used that is above the desired output power. This creates an optimal operating mode. However, this also means that current and voltage in the product can do more – the output power itself and a certain power window beyond that.
The principle works, as the load characteristics show (Fig. 4): If you run the induction furnace at full voltage and there is little scrap material in the furnace, little material couples and you run the furnace at low power. Even if the furnace operator adds more material and the furnace is half full, the point of 100% power at full voltage is reached, and even though only 60% of the electricity is used. If you add more material, it couples even better, uses more electricity, and the furnace needs less energy to drive more power in the process. This is the voltage reserve that can be used despite full power. In practice, however, material is sometimes added beyond this point, as the process then becomes simpler, since material has to be added less frequently and the workload is lower. However, this is not beneficial to the process, because if one were to stop filling the furnace sooner, the material fed in would be heated rapidly because the furnace would quickly couple up to the Curie temperature. The scrap then loses its magnetic properties, the coupling becomes worse – and the operation falls back one characteristic. Now you need more voltage again to drive the current to get to 100% power. However, as less and less material is magnetic, the current continues to decrease as the voltage is at its maximum level. The result is that the output drops. If material were to be added now instead, you would continue to have 100% power.
This system is essential for those switching from cupolas to induction furnaces because these operations often must cope with poorer scrap qualities, which is precisely what causes the coupling to deteriorate. They also rely on a ready supply of molten iron for their processes, which is why a control tool like OptiCharge is so valuable.
Conversion of the melting operation
To better evaluate how processes that use induction melting differ from those that incorporate a cupola as the melting unit, we will explain the specifics using three processes from actual practice.
Example 1: Flake-graphite cast iron brake discs
In the production of cast iron brake discs with lamellar graphite, the cupola can benefit from its advantageous nucleation state. However, the requirements for brake discs have increased considerably in recent years. As a result, the material is required to have high thermal conductivity, which can only be achieved if the cast material solidifies hypereutectically. In many cases, the carbon levels required for this cannot be produced directly by the cupola, so carburizing becomes necessary. In addition, the sound specifications to prevent squeaking of modern brake discs require carbon contents in narrow tolerances, which can only be produced by duplication in an induction furnace. All this is eliminated by melting in an electric induction furnace (Fig. 5).
The challenge in using an inductive melting method is, on the one hand, dynamic inoculation, which is technically easy to realize by adding an inoculation wire to the casting trough. Strontium as an element effective in inoculations is the agent of choice here. Another difficulty is the control of microporosities, which often occur at the transitions from cap to disc. Microporosities form between the arms of large austenite dendrites. In this context, the targeted use of lanthanum in the final inoculation step has proven helpful.
Example 2: Nodular graphite casting cast iron pipes
Nodular graphite cast iron pipes are manufactured using the centrifugal casting process. In the process, the cast iron pipe cools on the mold wall and forms iron carbides. Since iron carbide has a carbon content of 6.7%, the amount of free graphite produced during solidification is greatly reduced. As a result, the free graphite cannot counteract shrinkage when the liquid phase solidifies. This has the desired effect: the cast iron pipe shrinks and can be removed from the mold. The pipe is then passed through the annealing furnace, where the iron carbide dissolves and the graphite diffuses to the spherulites. The pipe expands and reaches its final dimensions. The original nucleation state from the melt aggregates directly influences the dimensions of the component.
A cupola produces a fluctuating metallurgical condition due to varying levels in the forehearth as well as changing metallurgy during start-up and shutdown cycles. The resulting dynamics in the nucleation state require a complex control loop when using a cupola, whereas this control is much simpler when melting in an electric induction furnace (Fig. 6).
Example 3: Vermicular graphite
Cast iron with vermicular graphite is found in the powertrain in the cylinder head, in the cylinder crankcases and in the clutch disks. This is a material for the mass market in heavy goods vehicle traffic. The material is also used in brake discs for high-speed trains.
When vermicular graphite is produced by adding desulfurized cupola iron, it is limited because the accompanying elements from the cupola can often exceed the final analytical specifications. The proportion of desulfurized iron can vary between 30 and 70% depending on the specification. When using this material, the cupola cannot effectively use its strong point, which is its naturally good nucleation state. The formation of vermiculites occurs with high levels of undercooling, while a good nucleation state automatically gives rise to spherulites due to metallurgical factors.
The control loop for vermicular graphite production modifies the melt by adding magnesium, cerium mixed metal and inoculant. This control loop uses the measured values from the thermal analysis of the ready-to-pour melt and retroactively corrects the control variables of the next ladle via a feedback loop. The fluctuations in the base iron caused by adding cupola iron are a disturbance variable here. A switch to iron completely melted in the induction furnace simplifies this process considerably (Fig. 7).
Planning and implementing the conversion
The engineering team
"What should the dimensions of our melting plant be?" "How can I increase productivity?" "Which upgrades will pay for themselves most quickly in terms of ROI?" – These are all questions foundry operators ask themselves when converting from cupolas to induction furnaces. And they are important questions, as they often entail large investments or can boost earnings. In order to be able to perfectly design, scale and plan a melting plant, ABP has developed the Meltshop Designer. This determines which solution is the best when it comes to material flow in the foundry. ABP experts can develop simulations for different foundry situations in close coordination with the customer's staff involved in the process, present alternatives when setting up the furnace, and include different configurations from the ladles to the filling of the molding system.
The metallurgical team
The metallurgical team must have expertise in cast iron production using the induction furnace as well as skills in producing the desired nucleation state. In contrast to the cupola, this is largely produced in a synthetic manner in the induction furnace. The metallurgical team creates a digital twin of the complete metallurgical process chain to evaluate and optimize all process steps in advance of the conversion from cupola to induction melting operation.
The energy efficiency of induction melting depends crucially on the sequence of materials to be batched and the timing of the recharging. These factors are incorporated into the Digital Twin's knowledge base, so the Zorc Genesis AI calculates batch composition and melt sequence based on this expertise. To determine the optimal time for charging, based on the current coupling and Curie temperature, ABP has developed the patented Opticharge tool mentioned earlier.
The synthetic nucleation state is generated in several stages. It starts in the furnace via the adding of silicon carbide (SiC), whose special physics during the dissolution process forms the basis for the nucleation state [5]. The next step in achieving the desired nucleation state for nodular graphite casting and vermicular graphite alloys involves adding cerium mixed metal (CerMM) and carbon prior to treatment. Cerium compounds have a high density and are not lost during the treatment process. In the production of thick-walled cast iron, it must of course be considered that cerium compounds can result in undesirable graphite shapes, up to and including chunky graphite. This requires a metallurgical balancing act in which the addition of elements such as antimony or bismuth creates an equilibrium that has a positive effect on graphite precipitation.
The interlinking of consulting services and production operations is a core feature of the metallurgical team. The service team's broad experience base enables them to provide comprehensive training to the production team. The production team, in turn, has precise knowledge of the foundry processes and brings with it a significant wealth of experience that must be incorporated into the process planning.
The specific implementation
Scheduling
The timeline for the conversion from a cupola to an induction melting unit is the biggest challenge and requires a strategic approach. It is a challenge for the planning team, the executing engineering team responsible for the implementation and the production team to use the newly established process chain. In the process, the condition of the existing production environment, including all integrated aggregates, must be converted to the newly designed process and plant technology, considering all parameters and influencing variables.
Engineering phase
The Meltshop Designer is used in the engineering phase, which is what makes its variability so valuable. ABP experts can simulate all materials by accessing or incorporating new materials into a large database. Various one-off or periodic events can also be simulated, for example power supply limitation, a not exactly uncommon problem in which energy providers reduce power supply at certain times when more power is currently being drawn elsewhere in the power grid. The basis for the simulation is data: The added value comes from the analysis performed by the ABP experts based on the linkage of the information. The simulation results in the recommended actions for moving from the cupola to the induction furnace.
Zorc's Genesis AI also works with data and uses the digital twin as a basis for controlling process flows. In the planning phase, it is used to simulate and optimize the processes in the newly designed melting operation. This helps to identify and avoid bottlenecks early in the planning process.
Transition of metallurgy from the cupola process to induction melting
While the cupola is still active, measurements of the metallurgical state are performed using thermal analysis, spectrometry and combustion analysis. Here, the precise mapping of the data is important to establish a link to the microstructural and mechanical properties obtained. This is provided by the service-oriented software Foundry Cloud developed by Zorc. Modern thermal analysis uses double-chamber crucibles to simulate the final stream inoculation or casting stone inoculation.
On the one hand, the data obtained during this phase are used to define the target parameters for the new melting process in such a way that the core parameters of the melt remain stable or improve during the conversion to ensure the smoothest possible transition during further processing of the components. This phase should last about four weeks to cover all metallurgical conditions. When the induction melting process is ramped up, it usually takes another four weeks for all aspects of the new process to be correctly mapped in the digital twin.
Tools for optimal planning and control of a modern production process
How is the metallurgy controlled and how are the transport logistics and the melt treatment and casting units controlled? Both can be answered in one sentence: with the Zorc Genesis AI, whose expertise is integrated into a digital twin. The Digital Twin mirrors the charging and melting process by replicating the physical processes in the furnace in a virtual environment. In doing so, it considers the pouring both in the charging troughs and in the furnace itself. It simulates the oxygen balance and the dynamics of the nucleation elements. It also describes the energy flow in the induction melting furnace, including the cooling capacity.
During the pouring and transport process, it tracks the interactions with the environment (atmospheric oxygen) and calculates the heat dissipation via convection and radiant heat. The Digital Twin has a comprehensive knowledge of the physics and chemistry of the wire feeding processes as well as the pour-over processes and simulates the associated nucleation processes. In the casting and solidification process, the twin performs simulation-based analysis to determine the effects of melt composition and nucleation state on part properties. In addition, the digital twin also keeps an eye on seemingly everyday processes: It calculates the duration of a forklift run, recognizes bottlenecks when tapping the iron and takes into account the break times of the forklift drivers.
Digital Twin Data Sources
To compare its forecasts with the current actual situation, the digital twin requires information about the current production status. The Digital Twin's "senses" are the measuring devices in the production environment. Traditional measuring instruments such as spectrometers determine the melt composition, while temperature measuring lances and pyrometers measure the bath temperature. Methods such as thermal analysis capture the dynamics of the solidification process and allow conclusions to be drawn about the nucleation state and graphite morphology.
Systems such as the Zorc Track & Trace are used to determine the position of forklifts, even in halls with "Indoor GPS", as well as to track the ladle position in the process flow. Service-oriented software such as the Foundry Cloud provides all the services required to read data sources such as measuring devices, PLC systems or IoT devices and convert them into a structured database.
And what is the AI doing? Production planning and process control
AI has the task of planning the next steps in the short, medium and long term in order to effectively solve the tasks set in the production process. Much like a chess computer, it searches for the optimal strategy. The way the task is formulated can influence the character of the production. The question is whether cost priority is higher than meeting deadlines or vice versa. All these factors can be adjusted with the help of parameters. The AI calculates optimal future trajectories while developing a plan that takes into account resources such as labor, energy consumption, electricity costs, etc.
Interaction with process owners and employees
The Zorc Genesis AI creates a workflow plan in much the same way that a navigation system suggests a route. Analogous to a navigation system, the human planner is not obliged to strictly adhere to this plan. Instead, he may deviate from it. The Genesis AI then calculates an adjusted workflow based on the new situation.
Tasks within the workflows are distributed via the Foundry Cloud to employees using mobile or stationary devices. The feedback is used by the Genesis AI to capture the current status of production and dynamically adapt workflows to deviating situations. A self-optimizing process: by following the procedure described above, production within FoundryCloud generates data that is used to refine all aspects of the Digital Twin. This, in turn, enables the Genesis AI to further optimize all aspects of production while learning from employee experience.
Conclusion
To achieve decarbonization targets, the transition of operations from fossil fuels to virtually carbon-neutral production is of great importance. How can foundries with cupola operations address the requirement for decarbonization? For the experts at ABP Induction and Zorc Technology, the solution lies in switching from cupola to induction furnace operation and controlling the processes using digital tools which incorporate AI. The induction furnace has clear advantages when operating with high-grade scrap, and additional tools such as ABP OptiCharge and the ABP Meltshop Designer can increase production capacity and throughput and improve energy efficiency. The flexibility of production with stringent quality requirements is achievable with the help of dynamic production planning and control using digitalization. The use of Zorc Genesis AI represents the next evolutionary stage of these systems and will result in increased efficiency even in complex production situations.
https://www.zorc-technology.com/
References
[1] Castings, show me your footprint! In: Foundry Planet, retrieved from: https://www.foundry-planet.com/d/castingsshow-me-your-footprint/
[2] A big step towards a small footprint. In: Foundry Planet, retrieved from: https://www.foundry-planet.com/d/abig-step-towards-a-small-footprint/
[3] M. Walz, R. Deike, EKALGU- Automatisierte Einblasanlage zur kalkbasierten Entschwefelung und Legierungseinstellung von Gusseisen, Herausgeber: Bundesministerium für Bildung und Forschung, 2020, retrieved from: https://r-plus-impuls.de/rplus-de/verbundprojekte/projekte/abgeschlossen/ekalgu.php
[4] Deike, R.; Brümmer, A.; Kahrl, A.; Smaha, B.; Walz, M.; Hentsch, R.; Baumgart, W.; Boenkendorf, U.: SubMag – Substitution von Magnesium bei der Entschwefelung von Gusseisen, in Innovative Technologien für Ressourceneffizienz – Strategische Metalle und Mineralien-Ergebnisse der Fördermaßnahme r³ (Hrsg. A. Dürkoop, C. P. Brandstetter, G.Grabe, L. Rentsch), Fraunhofer Verlag, Stuttgart, 2017, (ISBN: 978-3-8396-1102-9)
[5] Semleit, T., Adhiwiguna, I., Wijaya, J., Deike, R.: Investigation of silicon carbide dissolution behavior in molten cast iron under specific consideration of the formation of reaction layers, GIESSEREI Special 01/2021, 46-53, retrieved from https://doi.org/10.17185/duepublico/77012
The FRP®.DTG has standardized and easy to complete input-parameters leading directly to “C2C” in an instant. PPC and sales persons can collaborate easier and understand faster their manufacturing planning needs!
Here is one example of Input Parameters (Example for Sand Casting)
Example of Digital Twin generated (the FRP® - Resource Plan) with structure Level “Raw-Cast” leading to “Cost to Cast” (right picture):
Heunisch employs over 1200 people at a total of four locations.
This is a multifaceted campaign, as foundries are complex operations with casting quality relying on interrelated processes. In green sand casting applications, production of the sand mold and cores is one of the first and most critical elements. At the heart of this process you can find the molding sand materials themselves, as inadequate molding sands may cause a range of casting defects:
- Low strength molds or sand may result in cuts and washes, swelling and drops.
- Excessive permeability may result in metal penetration of the molding sand.
- Inadequate refractoriness of the sand may result in fusion defects.
- Excessive expansion of the sand when exposed to molten metal may result in rat tails.
Ensuring consistent quality of the molding sand material is therefore a vital task. Calderys has long offered routine mold sand analysis to its customers. The company is now bringing this process in Europe into the digitalized age with its CALDE® e-Support service, offering timely online access to testing results, as well as troubleshooting from the Calderys global network of experts.
Molding sand analysis and troubleshooting at your fingertips
Elisabeth van den Berg, Foundry Marketing Director at Calderys, explains:
“Customers regularly ask us to help them understand the quality of their molding sand – which contains our bentonite blends and additives – and how it is evolving over time. They are also asking for this information to be available online, when they need it. That’s how we developed the concept of CALDE® e-Support.”
CALDE® e-Support is designed to bring the reporting of molding sand testing closer to the foundry. Reports have been standardized across the Calderys network of testing laboratories and are currently delivered automatically to the customer’s inbox – but will be available in the future via a secure, online cloud-based portal.
Reports not only include the results for the particular batch of molding sand; now they also include statistical analysis of trends based on historical data. Crucially, they also offer troubleshooting and recommendations from a Calderys expert. The system is currently available in 4 languages; English, German, French and Italian.
“The aim of CALDE® e-Support is to go beyond simply reporting test results to help our customers digest the information and improve their process,” continues Elisabeth. “It is just one of the ways we are developing to share our technical expertise in a digital format.
“As the solution evolves, we will become more proactive in our responses, offering customized interpretation of the data and troubleshooting tailored to the specific customer application and needs.”
CALDE® e-Support has already been rolled out in Europe to customers of Calderys molding sand analysis services.
Customer-centric digital solutions
CALDE® e-Support is one of a growing number of digital solutions offered by Calderys that place customer pain points at the heart of product development. These pain points were identified over a series of interviews with foundry customers, and are:
- ease of doing business
- predictability
- efficiency
- safety and the environment
- access to technical expertise
“The aim of our digital program is to offer solutions that target these challenges,” says Elisabeth. “We see digital solutions as a means to an end. One of their key benefits is to provide a smoother way of doing business, for example, by facilitating easy and on-demand access to process data and analysis.
“Critically, they also facilitate access to technical skills and expertise that foundries may not have in-house, helping to optimize production, improve quality, lower costs, and reduce carbon emissions.”
This is particularly important for the foundry industry at a time when skilled manpower is becoming increasingly scarce. As a result, foundries are finding it difficult to recruit the necessary expertise. Solutions such as CALDE® e-Support mitigate this challenge by enabling access to Calderys expertise for troubleshooting and optimizing operations.
“Our experts become part of the foundry’s team, able to offer support and advice, even though they may be located on the other side of the world,” reflects Elisabeth. “As CALDE® e-Support evolves and the amount of data we have access to increases, this idea of continuous technical support will become a central part of the offering.”
Conclusion
In the digitalization of the industrial processes and the development of Foundry 4.0, molding sand mixes may not be the first thing to come to mind. CALDE® e-Support aims to change that and bring the analysis and reporting of molding sand testing into the 21 st century through:
- timely molding sand tests data availability
- a common system across our molding sand laboratories with a standardized system of reporting
- safe and secure storage of data with access to historical data and analysis
- the ability to customize reporting upon demand
- access to the Calderys network of experts.
“Green molding sand analysis may not be something foundries think a great deal about on a day-to-day basis. But master it and you have a strong foundation for improved sand mold and core production. And with that, a better casting process,” concludes Elisabeth. “CALDE® e-Support is your pathway to achieving that."
Despite the many possibilities offered by digital media, personal contact is still very important. Besides regular visits to customers on site, trade fairs are therefore still an important and indispensable platform for us and provide an update on the current market situation. We want to thank all our visitors for the interest shown.” Christian & Helmut Geiger Managing Directors
The GIFA 2023 from 12 to 16 June 2023 in Düsseldorf and than the 17th International China Diecasting from 12 to 14 July 2023 showed that personal contact is still appreciated.
Trends such as Giga-Casting and Sustainability were discussed in Germany and China as well and are being taken into account in further development work
In Shanghai, it was particularly interesting to see how far Giga-Casting has come. We are pleased that with our products we are a reliable partner for local users, both in the area of release agents and plunger lubricants.
The quality of the structural components produced is remarkable. In some cases processes are already ready for series production.
What is notable for us is the diversity of the approaches selected with regard to the use of release agents. Projects with water-free release agents, electrostatic application, water-based concentrates and conventional applications of water-miscible products are accompanied by us. In this context we can gain important new experience together with our customers.
The development of the Chinese foundry industry, the number of large machines on site and the ambitious plans for the future make this market even more interesting for us in the future.
We look forward to seeing you again at EUROGUSS 2024, which, as the trade fair for the die casting sector, is sure to attract many visitors again.
Sidrag AG uses very small die-casting moulds with sizes from 200 x 200 x 200 mm to 800 x 800 x 800 mm. Parts with weights of 3 - 4 g up to max. 3 - 4 kg are produced. The units are used for tempering mould inserts, mould frames, slides and nozzles.
Sidrag's challenge and core competence is its huge knowledge in the casting process and the processing of aluminium, zinc and magnesium. Sidrag is particularly challenged in the production of magnesium components; this is because liquid magnesium with a melt temperature of 650 °C hardens twice as fast as aluminium and therefore requires a high flow rate. In order to achieve stable temperature control and good heat dissipation, it is essential to have higher mould temperatures and the largest possible mould channels to optimise flow.
Therefore, eight 2-circuit oil temperature control units from Tool-Temp are used on several die casting machines. From different device generations, the TT-370/2, TT-380/2 to TT-388/2 perform at the highest level at continuous temperatures of 240 to 280 °C. The powerful and highquality 2-circuit units guarantee stable temperature control and trouble-free continuous operartion, even under tough everyday conditions, especially in the die-casting industry. The easy application of the units and their usability are appreciated by the employees. The equipment, which is fitted with time switches at the customer's request, in addition to various other additional features, ensures an even greater user-friendliness. Thanks to the pre-programmed, autonomous unit start, the heating process is already complete by the beginning of the shift.
2023 WFO Young Researchers and Early Career Conference 1st Best Paper
“High-performance sand castings by means of stair-step-free 3D printing”
Christoph Hartmann
Fraunhofer IGCV, Germany
Christoph Hartmann has a Master of Science in Mechanical Engineering and a Bachelor of Science in Business Administration, Management and Operations by the Technical University of Munich. Having worked as an Experimental Scientist in CSIRO, he is currently a Research Associate at Fraunhofer IGCV, Germany. He has been a PhD student during 2023.
CERABEADS® is a versatile material, favoured for its excellent properties such as good fluidity due to spherical shape, extremely low thermal expansion, and high heat resistance. CERABEADS® is produced from alumina-based raw material through a sintering process. CERABEADS® has a high recycling rate and almost no crystalline silica, which opens new possibilities for the use of this valuable material. CERABEADS® is a multiple solution.
About Resand Oy
Sand suitable for industrial use is becoming scarce. However, the extraction of virgin sand can be reduced, and the resulting loss of biodiversity slowed down by regenerating and reusing sand. Resand Oy is a Finnish technology company specialising in foundry sand regeneration, offering its customers clean sand as a service. The ResandTM solution enables almost 100% recycling of foundry sand and reduces CO2 emissions from sand use and transport by up to 80%.
Resand Oy is headquartered in Nuutajärvi, Finland, and has staff in several European countries. The company aims to achieve strong growth in the European foundry market and to expand its business outside Europe.
The ResandTM brings a solution to the global challenge by recycling sand - again and again and again.
About voxeljet
voxeljet is a leading provider of high-speed, large-format 3D printers and on-demand parts services to industrial and commercial customers. The company’s 3D printers employ a powder binding, additive manufacturing technology to produce parts using various material sets, which consist of particulate materials and proprietary chemical binding agents. The company provides its 3D printers and on-demand parts services to industrial and commercial customers serving the automotive, aerospace, film and entertainment, art and architecture, engineering, and consumer product end markets.
For more information, visit www.voxeljet.com or follow voxeljet on YouTube, LinkedIn, Facebook and Instagram.
About Itochu Ceratech Corp.
ITOCHU Corporation is one of the biggest conglomerates in Asia and ITOCHU Ceratech Corporation is a wholly owned subsidiary of ITOCHU and has been manufacturing high-quality ceramic products in Japan for 63 years.
CERABEADS® ceramic artificial foundry sand was developed in 1986 to offer foundries high-performance sand as a substitution for zircon sand. Since that time foundries all over the world have enjoyed benefits connected with the usage of CERABEADS®, such as high refractoriness, almost zero thermal expansion, high durability, and almost no crystalline silica content. In recent 15 years, the demand from foundries to reclaim sand has increased globally to reduce the waste of limited natural sources, improve the foundry environment, and focus on the production of complex castings. Nowadays, foundries use CERABEADS® in various industrial sectors and metals in automotive, aerospace, heavy industry, and 3D printed sand parts.
For more information, visit www.itc-cera.co.jp/english/
CASTINGS & FOUNDRIES EXPO INDIA
A Trade Show of Indian Foundries & Castings, Foundry Equipment and Suppliers
Indian castings are internationally competitive in terms of quality and cost and the Indian Foundry industry is the second largest in the world. At this opportune time when the world looks towards India for economic growth, the CASTINGS & FOUNDRIES EXPO INDIA will serve as a veritable International bazaar of Indian foundries and castings attracting top buyers from India and abroad.
Being concurrent to ENGIMACH, significant synergy will be created between the two shows. While ENGIMACH is a show of the latest technology and innovations in manufacturing, CASTINGS AND FOUNDRIES EXPO INDIA will display products of one of the oldest and foundational manufacturing process.
GIFA Indonesia 2023, the 1st International Foundry Fair and Forum for Indonesia, will be held in Jakarta, Indonesia, at Jakarta International Expo (JI Expo), showcasing foundry systems. This includes casting machines and technologies, pouring equipment, molding, core making, die making, and more.
The event is open to all industry professionals and business owners in the metal industry value chain, including foundries, refractories, mills, casting plants, as well as those interacting with business partners from sales and procurement offices.
Join MAGMA and our partners, Frech Asia, at Hall C1, Booth 6317 (German Pavilion), where we will showcase our products and innovative solutions. These will assist you in optimizing your casting processes while focusing on sustainability!
GIFA Indonesia 2023 provides free admission for business and trade visitors, ensuring easy accessibility for professionals in the foundry industry. This enables you to explore the exhibition, attend seminars, and engage with exhibitors without encountering any financial barriers.
Event: GIFA Indonesia 2023
Date: September 13th to 16th, 2023
Venue: JI Expo, Jakarta, Indonesia
GIFA Technical Conference Registration: Registration for both the physical and online conference has started. Click here to view the conference agenda and proceed with your registration.
YIZUMI has achieved another significant breakthrough in the realm of ultra-large machinery after the delivery of the 8500T ultra-large injection molding machine. It's a pivotal milestone for YIZUMI in the field of metal forming.
The LEAP 7000T ultra-large die-casting machines, a culmination of relentless research and innovation by YIZUMI, are poised to meet the demand of integrated die-casting in NEV manufacturing.
Empowering the Future of Integrated Die-casting for Changan Auto
As a vanguard in automotive manufacturing, Changan Auto has always set up the integrated die-casting in its strategic development of lightweight, with the boomer development of NEV. The 7000T machines will be applied to produce front and rear floor panels for new NEVs. It further strengthens Changan’s competitive edge in the realm of integrated die-casting.
Beyond this, the international satellite trade fairs of The Bright World of Metals will provide opportunities for face-2-face exchange in the meantime. The global portfolio for the sectors of industry covered by GIFA, METEC, THERMPROCESS and NEWCAST includes the following events:
- 11–14 September 2024 GIFA/METEC Indonesia – Jakarta, Indonesia International Foundry and Metallurgical Trade Fairs and Forums for Indonesia
- 25–28 September 2024 THERMPROCESS China – Shanghai, China International Trade Fair for Thermal Process Technology
- 16–18 October 2024 GIFA Mexico – Mexico City, Mexico International Foundry Trade Fair and Forum for Latin America
- 27–29 November 2024 METEC India – Mumbai, India International Metallurgical Technology, Processes and Metal Products Trade Fair
- 17–19 September 2025 GIFA/METEC Southeast Asia – Bangkok, Thailand International Foundry and Metallurgical Trade Fairs and Forums for Thailand
- 2025 GIFA/METEC Middle East Africa – Cairo, Egypt at Metal & Steel Middle East 2025
1 – CO2 reduction: More than 800 thousand MT of CO2 were saved in 2022 compared to 2020
CLEPA’s CO2 tracker shows a substantial reduction of 856.000 metric tons, equivalent to the emissions of a mid-sized French city like Grenoble. This represents a significant improvement, with emissions reductions shifting from -0.2% between 2020 and 2021, to a noteworthy -4.5% between 2021 and 2022, setting a positive trajectory for the future.
This year's congress was a great opportunity for COSTAMP Group to strengthen their relationship with customers and partners across the ocean, as well as gathering information about the current market trends
GIGA was the main principle of the show
It was not a surprise that GIGA was the main principle of the show and the backdrop, which were presented at booth – so that everything was perfectly in line with this disruptive topic, which is shaping the new automotive industry.
2 – Renewable energy: Share of renewable energy peaks at 41% in 2022
Rapid adoption of renewable energy sources has played a pivotal role in decarbonising production. Renewables accounted for just 13% of the overall energy use in 2020 but surged by 128% between the base year and 2021, followed by a further 64% increase between 2021 and 2022. Last year, the share of renewable energy increased to 41% of automotive suppliers’ total energy consumption.
To sustain and increase this trend, support for a stable and timely supply of green electricity is crucial. Additionally, sectors heavily reliant on gas, such as iron and steel casting and glass manufacturing, will require hydrogen for full decarbonisation. Here, the switch from gas to renewables with no disruption in the transition will only be possible if green hydrogen is widely available and affordable.
3 – Water use: Increased vehicle production puts a spotlight on water use
Water usage in suppliers’ production increased by 10% between 2020 and 2022, slightly outpacing the growth in vehicle production over the same period (from 78 million vehicles in 2020 to 85 million vehicles in 2022, according to OICA).
Companies are developing strategies to minimise resource waste and to mitigate climate change. Future goals include decoupling water consumption from production levels.
4 – Waste management: Up to 93% of production waste was recycled or recovered in 2022
Similar to water consumption, waste generation grew by approximately 9% over the past two years, but suppliers reported a slight increase in the recycling and recovery of waste, rising from 92% to 93% in 2022. Recycling rates have traditionally been high in the automotive supply industry, with a focus on reusing production waste. Initiatives now extend to remanufacturing components and producing new components from recovered waste, enhancing sustainability across the industry.
About The Bright World of Metals:
The Bright World of Metals comprising the trade fairs GIFA (16th International Foundry Trade Fair with Technical Forum), METEC (12th International Metallurgy Trade Fair with Congresses), THERMPROCESS (14th International Trade Fair and Symposium for Thermoprocess Technology), and NEWCAST (7th International Trade Fair for Castings with NEWCAST Forum) is considered the pioneering platform for trends and technological innovations in the metallurgy and foundry technology sectors the world over. Registering 2,188 exhibitors and 63,262 visitors from 116 countries the trade fair quartet consolidated its position as the global market leader in this important sector of industry in 2023. Especially the hot topics ecoMetals, circular economy and Artificial Intelligence met with great interest among trade visitors. Likewise, the themes of lightweight construction and innovative manufacturing technologies played a prominent role – as highlighted not least during the ecoMetals-Trails.
GIFA, METEC, THERMPROCESS and NEWCAST 2027 promise to become extraordinary events again, set to further drive developments in the sector and intensify international business relations.
Experiences in cutting-edge technologies
COSTAMP also took the chance to prove that in it’s involvement and contribution in several GIGA TOOL projects, which has allowed them to develop a remarkable experience in this cutting-edge technology.
Sometimes they were overwhelmed by the presence of unexpected visitors stopping by and filled with pride - with an extra boost to do even better in the future.
So far, NADCA has therefore been crucial to COSTAMPs business. The American market is growing year by year, and they are gearing up to continously strengthen presence in the US.
2023 was a year with a lot of celebrations for COSTAMP and 2024 will go on like this. Because the company will be exhibiting at Euroguss in Nuremberg, at NADCA Show in Indianapolis and at Fundiexpo in Monterrey!
In conclusion, we can summarize that COSTAMP is looking forward to all these events, that are great occasions to be surprised by new global solutions.
YIZUMI ultra-large die-casting machine were well recognized by customers
Focusing on the new strategy, the LEAP series die-casting machine was mutually developed by international R&D team with decades of experience in die-casting. To integrating advanced technologies from China and Europe, YIZUMI has conducted independent research and development in an all-round way and owned completely independent intellectual property rights. LEAP series not only can satisfy the higher requirement of the rapid development of die-casting industry on the performance, function and complete die-casting process, it could also provide smart solutions to better understand demands from customers. It adapts different types of complicated die-casting process and makes die-casting easier.
When the LEAP series debuted to public since July 2021, YIZUMI has developed die-casting machine size from medium to ultra-large of the LEAP series ranging from 380T to 9000T.
The delivery of the LEAP 7000T to Changan Auto not only heralds a momentous achievement for YIZUMI but also signifies China's rising prowess in the global manufacturing arena. With development of integrated die-casting, ultra-large die-casting machines remains the ineluctable trajectory of global manufacturing. The symbiotic collaboration marks the passage into a new era of NEV manufacturing and has laid the groundwork for the development of NEV revolution.
2023 WFO Young Researchers and Early Career Conference 2nd Best Paper
“Impact of Aluminium on Silicon Distribution in High Silicon Spheroidal Graphite Iron by Performing 3D-Microstructure Simulations”
Betto David Joseph
RWTH Aachen, Germany
Betto David Joseph has a Master of Science in Metallurgical Engineering Process by RWTH Aachen University, where he is now a PhD student in Metallurgical Engineering. His work experience includes having been a Quality Control Inspector at Suguna Pumps & Motors, Kalapatti, and a Student Assistant at Institute IME Process Metallurgy and Metal Recycling. He is currently a Research Associate at Gießerei-Institut in RWTH Aachen University.
16TH ENGIMACH
India’s 2nd largest trade show of Engineering Machinery, Machine Tools, Manufacturing and Automation.
The preceding 15th edition, held from 1-5 December, 2021 in challenging post-Covid times and discovery of the Omicron variant, was nonetheless officially designated as a PRE-VIBRANT GUJARAT EVENT and featured 427 Exhibitors, 15 Exhibiting Countries and 72,503 Visitors!
ENGIMACH Exhibitor Categories (BUYERS OF CASTINGS)
- Machine Tools - Cutting
- Machine Tools - Forming
- Machine Tools Accessories
- Precision Tools
- Gears, Motors & Drives
- Air Compressor
- ITES (Software)
- Welding Equipment & Consumables
- Hydraulics & Pneumatics
- Additive Manufacturing
- Tube & Pipe Technology
- Robotics & Automation
- Pumps & Valves
- Material Handling, Storage & Logistics
- Industrial Supplies
- Newly Launched & SPMS
- Surface Finishing & Blasting
- Power Tools & Hand Tools
- Fastener & Hardware
- Testing & Measuring
- Industrial Safety
2023 WFO Young Researchers and Early Career Conference 3rd Best Paper
“Prediction of shrinkage porosity in cast Mg alloys: Formation tendency and prediction criterion”
Ang Zhang
Chongqing University, China
Ang Zhang obtained a PhD degree at Tsinghua University, China, and he currently works as an Associate Professor at Chongqing University, where he is developing research activities in Materials Engineering.
UNIQUE ATTRACTIONS FOR INDIAN FOUNDRIES
700+ Castings Buyers expected at the venue itself as Exhibitors in 16th ENGIMACH
70000+ Visitors from diverse industrial segments expected at 16th ENGIMACH
Sponsored international buyers at International Buyer - Seller Meet
Invited sourcing teams from key industrial sectors like Railways, Automobile etc.
Complimentary participation in Buyer-Seller Meet for exhibitors
Paid participation in Buyer-Seller Meet for non-exhibitors
Exhibitor Profile of Castings & Foundries Expo
- S. G. Iron
- Grey Iron
- Steel & Alloy Steels
- Investment Casting
- Lost Foam Castings
- Aluminum Die Castings
- Non Ferrous & Others
- Foundry Chemicals
- Foundry Plants / Machines
- Die-Castings Machines and Plants
- Furnaces and Accessories
- Sand Preparations, Treatment Reclamation
- Automation / Robotics
- Material Testing & Handling Technology
Visitor Profile
Decision Makers, CEO Level Professionals, R & D Personnel, Technical Managers, Industry Consultant, Sales & Purchase Managers, Production Managers, Investors, Engineers and Contractors, Marketing & Distribution Personnel, Industry Expert and Government Officials
More Information at: www.castingsandfoundries.com
Tool-Temp offers customised solutions to optimise production processes. Especially for Sidrag's magnesium application, five TT-168 E/PHE temperature control units were modified for operation with heat transfer oils. Here, only nozzles and individual slides are cooled between 20 - 40 °C. Due to the high melting temperatures of the magnesium of 620 - 640 °C, a very high cooling capacity is required to dissipate the heat.
Tool-Temp supports its customers with comprehensive services from a single source. Sidrag AG is also very satisfied with the services, which fully meet their expectations. Particularly important are the short delivery routes, the permanent availability of spare parts with fast delivery times, as well as the fast response times with customised support and solution proposals.
"The geographical location of the company, the highly competent contacts who are available to us whenever we need them, either in the sales, service or spares departments had been instrumental in our long standing supplier customer relationship which continues to this day. The high quality materials and the experience with Tool-Temp equipment is unrivalled”, concluded Luis Gil.
About Tool-Temp
The Swiss Tool-Temp AG is a globally operating company that offers complete solutions for temperature control and cooling equipment. As a family business in second generation, Tool-Temp AG focuses on the durability and simplicity of its products. Production takes place exclusively at the company's headquarters in Switzerland. The product range includes water/oil temperature control units, water temperature control units, pressurised water temperature control units, oil temperature control units and cooling units. With 16 subsidiaries and 30 distributors, Tool-Temp AG has a wide sales and service network worldwide. tool-temp.ch
Investment and trade data suggest that the EU's automotive industry may be losing its competitive edge
What you will find in this edition
1 - EU auto suppliers maintain slight edge in market share amidst stagnation
2 - US continues to outperform the EU as an investment destination
3 - EU suppliers face FDI decline and new challengers
4 - EU’s export dominance of conventional components seeing growing pressure
5 - Battery imports dent EU’s trade surplus
As the EU grappled with a staggering trade deficit of €440 billion in 2022, Europe’s automotive industry generated a trade surplus of more than €110 billion. Defying the odds, this industry remains a vital pillar of the EU economy, contributing €25 billion to this surplus. However, subtle tremors are becoming evident. The industry’s robustness is being threatened by the mounting challenges that undermine its competitive standing. Despite ambitious investments in the battery supply chain, the import of batteries has chipped away at the once-strong trade surplus for auto components, eroding more than 60% since 2018.
Across the span of 18 months, the US has witnessed a remarkable surge, attracting almost three times the investment the EU has managed to secure within the auto supply and battery sector. And perhaps most concerning, auto suppliers find themselves at a crossroads, beginning to relinquish their market share concerning foreign direct investment. It’s a picture of resilience, combined with vulnerabilities, urging the industry to navigate a shifting landscape in order to safeguard its pivotal role within the European economy.
"EU suppliers built a global lead in the previous decade, resulting in an annual trade surplus close to €30 billion. If the current growth of battery imports continues, in 2024, the EU could become a net importer of automotive components." Nils Poel - CLEPA's Deputy Head of Market Affairs
1 - EU automotive suppliers maintain slight edge in market share amidst stagnation
Amid a period of stagnation, the EU’s automotive suppliers continue to hold a slightly higher global market share (15.9%) compared to the broader manufacturing sector (15.7%). However, both sectors remain below pre-COVID levels.
Rockman serves its customers through strategically located facilities in auto clusters in the north, west, and south of India. Each of the facilities is designed for high quality and volumes, cumulatively converting over 240k+MT of aluminum annually. With over 100 HPDC, 200 GDC, 30 LPDC, and 450 CNC, VMC, and HMC machines, Rockman is a one-stop shop having all three casting processes (GDC, LPDC, and HPDC) with end-to-end capabilities including design, engineering, casting, machining, painting, and assembly. The combination of these technologies has empowered Rockman to build a vast portfolio of products and capabilities to suit every need. Rockman is the largest producer of two-wheeler alloy wheels and the fastest-growing four-wheeler alloy wheel manufacturer in India with an installed capacity of 16Mn+ and an FY24 projected capacity of 17Mn+ alloy wheels annually. In addition to its stronghold in casting, the company also manufactures motorcycle and industrial chains with an annual production capacity of 20Mn+ meters.
Rockman is currently focused on increasing its capacity across its various wheels, casting, and chain divisions in order to cater to its customers’ growing demand. It is Rockman’s constant endeavor to make its presence known in the export market with current focus, offices, and key account managers present across the US and Europe. Being technologically driven, Rockman’s investment in Industry 4.0 technologies with cloud processing enables it to achieve manufacturing excellence, increased productivity, and higher quality. Considering the rising trend in the automobile industry, Rockman has developed its capabilities to support the production of structural parts and other casting components. Leveraging years of expertise to produce high-quality products that meet global standards with benchmarked precision, reliability, and innovation, Rockman has made itself known as a trusted partner for all of its clients.
A precise and gentle finishing process that maintains the geometrical integrity of the work pieces
During the dry electropolishing process the work pieces, mounted to a fixture, are slowly moving through the dry electrolyte. This ensures complete coverage of the entire surface. If required, internal surface areas can also be finished by using special electrodes. The DryLyte method removes primarily the roughness peaks from the surface. Therefore, the metal removal rate is minimal, and the overall process is very gentle. The finished work pieces have a highly homogeneous surface with no pressure points or an orange peel effect. Even in the case of delicate work pieces with complex shapes no damage in the form of scratches or breakage occurs.
The targeted and “controlled” processing ensures that in case of precision components like machining tools or tools for the pharmaceutical industry their geometrical integrity is not affected, and their edges are not radiused. In addition, the highly effective smoothing effect on the surface prevents micro cracks and pitting. This improves the corrosion resistance and “fatigue” characteristics and, thus, extends the usable life of the components. Compared to components treated with traditional electropolishing, dry electropolished components corrode 4 to 15 times slower as proven in corrosion tests in a saltwater solution containing 30 grams/liter NaCL. In the case of gear components used in mechanical systems, dry electropolishing increases the material load ratio, reduces friction and guarantees the optimal distribution of lubricants on the work piece surface. The improved surface conditions result in a lower wear rate and, at the same time, reduce the noise level. Another significant benefit of the DryLyte technology are the relatively short cycle times. Depending on the finishing application, initial surface roughness and required results, they can vary between a few minutes and 1.5 hours. The process creates not only a smoother surface but, if needed it can also produce a high gloss polish in one single process. For post processing of 3D printed components with their typically very high surface roughness, the electropolishing operation is preceded by a mass finishing process utilizing abrasive grinding media.
Easy adaptation to many finishing applications
The unique, patented dry electropolishing technology was initially developed for finishing prototype castings and dental crowns made from cobalt chrome and titanium. In the meantime the dry electropolishing method from GPA Innova is used for finishing stainless steel, steel, hard metals as well as nickel, aluminum and copper alloys along with other conductive metals. Today the process is used whenever high finishing qualities are required in industries such as aerospace, pharmaceutical, machine building as well as luxury and consumer goods. Because of the proven biocompatibility of the finished components dry electropolishing is also used in medial engineering for the production of implants and instruments. Process development and definition of the process parameters for the respective finishing application takes place in the customer experience center at Rösler. For this purpose, the CEC is equipped with different machine types allowing fully automatic operation. This approach guarantees that the finishing processes for the customer components are always based on precisely defined and validated parameters.
Optimum mechanical strength and elongation
Area of application: vehicle components, chassis parts, chassis-relevant components
Up to 60% less weight
Compared to steel parts, higher fatigue strength, ideal for automotive applications
Excellent weldability and compressive strength
Application range: vehicle components, chassis parts, pressure vessels, coolers, pumps
Best thermal and electrical conductivity
20% higher thermal conductivity Application area: telecommunications, battery technology, line electronics
No post-processing necessary
Cost effective as no milling, deburring or grinding required. Applications: Visible components, interior parts, brake discs.
Program S2P 2023
-
View program 125 KB
2 - US continues to outperform the EU as an automotive investment destination
Foreign direct investment (FDI) continues to flow into the EU’s automotive supply chain, albeit with a significant gap compared to the US. Over the last 18 months, non-EU companies invested over €14.3 billion into the EU, while the US attracted a staggering €42.8 billion during the same period. Further, the US is surging ahead in battery production capacity, leaving important question marks on EU industrial policy.
3 - EU suppliers face FDI decline and new challengers
Although EU-based automotive suppliers recorded investments of €16.4 billion outside the EU in 2022 and the first half of 2023, their share of global FDI has dwindled from 43% in the first half of 2022 to just 12% over the same period in 2023. South Korean companies like Samsung, LG, and Hyundai are increasingly posing a challenge to the EU’s FDI dominance, investing €17.5 billion in the US battery supply chain. Meanwhile, US suppliers surpassed EU suppliers in terms of investment for the first time since 2018.
“Automotive suppliers continue to outperform, but the EU is losing ground. Policymakers have established a framework towards 2030 with ambitious environmental and societal goals, requiring swift and strategic responses to maintain competitiveness in a rapidly evolving landscape." Benjamin Krieger - CLEPA's Secretary General
4 - EU’s export dominance of conventional components seeing growing pressure
In 2022, the EU’s automotive supply industry achieved an export total of €51.7 billion, maintaining its global lead. However, this dominance is gradually eroding with China’s exports growing by 9% during 2022, while the EU recorded an 8% decline. As the gap narrows, it could be that this year or the next marks the year that China takes over. This unfolding trend underscores the EU’s stagnation amid its competitors’ growth.
5 - Battery imports dent EU’s trade surplus
The EU's automotive components trade surplus dipped by 11% in 2022 and plummeted by 56% when including battery trade. Li-ion batteries surged threefold in terms of total trade value in 2022 compared to the previous year. Although investments in the EU battery supply chain should eventually mitigate imports, the import value of batteries in Q1 2023 have almost doubled compared to the same period in 2022. Simultaneously, sales of battery electric vehicles grew by over 53.8% across the EU in H1 2023.
Key Facts - Procceses
HPDC:
-
India’s first hot metal transfer from alloying unit to shop floor
-
Annual processing capacity of 45,000 tons of aluminium casting
-
Casting components as heavy as 6.5 kg
-
Daily production of over 1,80,000 components
-
Over 103 HPDC machines from 250T-1250T, expanding 1650/1800T
-
Processing more than 12 types of alloys
LPDC:
-
In house core manufacturing
-
Annual processing capacity of 10,000 tons of aluminium casting
-
Over 27 LPDC machines
-
Daily production of over 27,000 components.
-
In-house facility for T6 Heat Treatment
-
Porosity inspection using state-of-the-art X-Ray
-
Inspection with 3D CT capabilities
-
4 Wheeler Alloy wheel +Parts Manufacturing
GDC:
-
Integrated manufacturing facility for GDC parts
-
Over 152 GDC machines
-
Annual processing capacity of 50,000 tons of aluminium casting
-
Largest 2 Wheeler Alloy wheel Manufacturing
Copyright: SAG, Fotografin: Karin Pasterer
Full freedom of design
Different wall thicknesses possible, high functional integration in the field of bionics. Weight optimization with the same installation space
In summary, it can be concluded that amazing results can be achieved with the rheocasting process. The high strength and ductility, very good weldability and conductivity of rheocasting components enable efficient lightweight construction in many areas. Less weight leads to more range and lower energy consumption. Rheocasting can thus contribute to CO2 emission reduction with considerable weight savings. More efficiency in the production process: Rheocasting can avoid costly reworking of castings. The engineers at SAG were the first to industrialize the rheocasting process and today also offer large series of up to 400,000 parts.
Among the impressive components Fabian Hofstätter presented in his paper in Aalen were helium pressure-tight components, air spring tool systems. For these components, the low porosity of the material, the strength and the outstanding mechanical properties are particularly important.
If you would like to take a closer look at this topic or ask the SAG experts questions directly, you will soon have the opportunity to do so in Munich at the IAA Mobility 2023 from 5 September to 10 September 2023.
Meet the SAG experts in Hall B1/E 20!
Innovative, sustainable, international
SAG is an internationally active company with Austrian roots. Thanks to highly trained employees, tank solutions and lightweight components for vehicle construction are developed and produced at a total of 10 locations in Europe, Mexico and the USA. The R&D know-how as well as the product and service portfolio are constantly being expanded. SAG is a technology leader in many areas of the materials sector and in the field of cryogenic tanks.
Aluminium brings lightness to vehicle construction. Due to its low weight and corrosion resistance, it has excellent mechanical properties. In addition, it is extremely versatile, 100% recyclable without any loss of quality and thus a very resource-saving raw material.
SAG is the world market leader in the field of rheocasting.
The Salzburger Aluminium Group has been successfully supplying international customers with its innovative quality products for many years - from the automotive, railway and aviation industries to the energy sector.
Post Processing Capabilities
-
Precison Machining
-
Surface Treatment | Liquid Paint Shop
-
Assembly shop
Product Range:
Casting Products --> Alloy Wheels (2W, e-2W & 4W) | Housing, Cases, Covers (Complete Range of HPDC, LPDC & GDC Products)
Automotive Chains --> Drive Chains & Cam Chains | Two-Wheeler Chains and Cam Chains
E V Housings & Structural Parts --> Aluminum Housing Components | Battery Housing, Transmission Housing, Motor Housing, Heat Sink and ECU case
Four Wheeler Product Range:
-
Servo Motor Housing
-
Cover Cylinder Head
-
Cylinder Block
-
Pan Oil Upper
-
Electronic Throttle Body
-
Transmission Housings
-
Alloy Wheels
-
Flange housing, VOP housing and cover & ETB
-
Shift Fork Assemblies
-
Fuel Pump, Water Pump Housings
-
EPS Motor Housing
-
ECU Housing
-
Brake System Parts
Two Wheeler Product Range
-
Crank Cases
-
Fuel Pump Housings
-
Aluminium Alloy Wheels
-
Engine Housings and Covers
-
Chains
-
Drum Brake Assy.
-
Swing Arms
-
Casted Frame Parts
-
ECU Covers
-
Cylinder Heads
Parts Specific to EV Industry
-
Motor Housing
-
Heat Sink
-
Motor Mounting Frame
-
Side Frame Part
-
Rear Frame part
-
Swing Arm
Contact Persons:
RFQs & Enquiries
Rajiv Swaminathan
rajiv@rockman.in
+918248353134
Strategic Alliances
Aditya Bansal
aditya.bansal@rockman.in
+919764946803
PROGRAM - 63. IFC Portorož 2023
16.30–19.30 Registration of participants at the Conference reception desk / Prijava udeležencev na recepciji konference
17.30 Bus transfer from Hotel Slovenia to Piran / Avtobusni prevoz od Hotela Slovenije do Pirana
18.00 Reception in the garden of the Cultural Center Georgios – in the church of St. Jurij – With a greeting from the representative of the County of the Municipality of Piran / Sprejem na vrtu Kulturnega centra Georgios pri cerkvi sv. Jurija s pozdravnim nagovorom predstavnika županstva Občine Piran
Thursday / Četrtek, 14. 09. 2023
7.30–further / dalje Registration of participants at the Conference reception desk
Plenary lectures
9.30–9.45 MIRJAM JAN–BLAŽIĆ,
President / Predsednica Slovenian Foundrymen Society
The Opening Address/ Uvodni nagovor
9.45–10.15 M. BOSSE, BDG-Service GmbH (DE): Decarbonisation Paths for the Foundry Industry / Razogličevalne poti v livarstvu
10.15–10.45 D. HOWE, G. GEIER, Siempelkamp Giesserei GmbH (DE): Transformation in the Iron Foundry in Europe: Keys for Technical and Economic Success / Prilagoditve v evropskih livarnah sive litine: ključ do tehnološkega in ekonomskega uspeha
10.45–11.15 P. MRVAR1, M. PETRIČ1, S. KASTELIC2, A. KRIŽMAN3, HEINZ PALKOWSKI4, 1Faculty of Natural Sciences and Engineering of University of Ljubljana, 2TC Livarstvo d.o.o., 3University of Maribor, (SI), 4TU Clausthal (DE): Manufacturing and Characterization of Composed Foam Castings from Biodegradable Zn-Mg Alloy and Salt / Izdelava in karakterizacija sestavljenih ulitih pen iz bio-razgradljive zlitine Zn-Mg ter soli
11.15–11.45 Break / Odmor
11.45–12.25 K. WEISS, C. BAITIANG, RWP GmbH (DE): Digitization as the Basis for Proactive Foundry Management / Digitalizacija kot osnova za proaktivno upravljanje livarn
12.25–12.45 P. HOFER-HAUSER, R. GSCHWANDTNER, Austrian Foundry Research Institute (AT): Thermal Shock Resistance of Conformally Cooled Core Pins for Die Casting Applications / Odpornost na termične šoke komfortno hlajenih vložkov v aplikacijah tlačnega litja
12.45–13.15 M. FIROOZBAKHT, A. BÜHRIG-POLACZEK, RWTH Aachen University (DE): Proactive, Innovative and Flexible Foundry Institute – Investment Casting Research Group / Proaktiven, inovativen in prilagodljiv inštitut za livarstvo – Skupina za raziskavo precizijskega litja
13.15–15.15 Lunch Break / Kosilo
15.15–15.45 J. MEDVED1, M. VONČINA1, T. BALAŠKO1, V. NAHTIGAL2, 1Faculty of Natural Sciences and Engineering of University of Ljubljana, 2Chamber of Commerce and Industry of Slovenia, (SI): The Importance of Critical Raw Materials for the Sustainable Development of Metallurgical Companies / Pomen kritičnih surovin za trajnostni razvoj metalurških podjetij
15.45–16.15 A. NOFAL, Central Metallurgical Research and Development Institute (CMRDI) (EG): Fifty Years of Cast Iron Research at CMRDI / Petdeset let raziskav sive litine na CMRDI
16.15–16.30 Break / Odmor
16.30–17.00 T. KAUFMANN, D. HARTMANN, Kempten University of Applied Sciences IPI – Institute for Production and Information Technology (TTZ Sonthofen) (DE): Applied Machine Learning and Optimisation in Steel Melting / Uporaba strojnega učenja in optimizacija pri taljenju jekla
17.00–17.30 Z. Zovko Brodarac1, F. Kozina1, J. Medved2, J. Burja3, 1University of Zagreb Faculty of Metallurgy (CRO), 2Faculty of Natural Sciences and Engineering of University of Ljubljana (SI), 3Institute of Metals and Technology, Ljubljana, Slovenia: Investigation of Recycled AlSi9Cu3(Fe) Alloy / Preiskava reciklirane zlitine AlSi9Cu3(Fe)
Thursday Evening
19.30 Foundrymen night on the coastline / Livarska noč na obali
Friday / Petek, 15. 09. 2023
SECTION / SEKCIJA A: Cast Iron, Foundry Techniques and Technology
9.00–9.20 M. PESCI, HA ITALIA S.p.A. (IT): New Chemex Insert Sleeves for The Reduction of Feeding Volume / Novi vložki Chemex za zmanjšanje volumna napajanja
9.20–9.40 A. HARBORTH, V. AFANASEV, Volume Graphics GmbH (DE): Industrial CT: Quality Control and Process Optimization in the Casting Process With the Help of Non-Destructive Examinations (NDE) / Industrijski CT: Kontrola kakovosti in optimizacija procesa v livarstvu s pomočjo neporušnih preiskav
9.40–10.00 D. MOLNAR, University of Miskolc (HU): Development of a Duplex Casting Method / Razvoj metode dupleksnega litja
10.00–10.15 Break / Odmor
10.15–10.35 C. ABT, F. WOHLGEMUTH, HEITEC PTS GmbH (DE): Fast and Flexible Inline X-Ray Testing in Foundries Using Modular Concepts / Hitro in fleksibilno rentgensko testiranje v livarnah z uporabo modularnega koncepta
10.35–10.55 K.VAN NIEKERK1,2, 1Lauds Foundry Equipment Gmbh (DE), Siapro
d.o.o. (SI): Cold Box Core Machines / Stroji za cold box jedra
10.55–11.15 E. OFFENBACHER, LHS Clean Air Systems (AT): Green Foundry – Advanced Dedusting With Combined Heat Recovery / Napredno razpraševanje kombinirano z regeneracije toplote
11.15–11.30 Break / Odmor
11.30–11.50 I. ADHIWIGUNA, R. DEIKE, Universität Duisburg Essen (DE): Reassessing the Role of Magnesium: In Search to a Sustainable Alternative in Cast Iron Production / Ponovna ocena vloge magnezija: V iskanju ustrezne trajne alternative v proizvodnji sive litine
11.50–12.10 A. MAJUMDAR, C. PALANISAMI, A. BÜHRIG-POLACZEK, Giesserei Institute, RWTH Aachen (DE): Correlation of Microstructural Analysis of Spheroidal Graphite Cast Iron Grades by Varying the Silicon Content / Povezovanje mikrostrukturnih analiz nodularne sive litine s spreminjanjem deleža silicija
12.10-12.30 Luka Krajnc1, Marko Bojinović1, Grega Klančnik1, Andrej Resnik2, 1Pro Labor d.o.o., 2OMCO Metals Slovenia d.o.o., (SI): Case Study of Digital and Circular Transformation Interaction in Foundries / Študija primera integracije digitalnega in krožnega prehoda v livarnah
12.30-12.45 Break/Odmor
12.45–13.05 L. LAZIC, M. POKRIVAC, I. JANDRLIC, Faculty of Metallurgy of University of Zagreb (CRO): Technological and Structural Calculation of the Recuperator for Air Preheating on the Cupola Furnace / Tehnološka in strukturna kalkulacija rekuperatorja za segrevanje zraka pri kupolni peči
13.05-13.25 J.TROJAN, Norican Czech s.r.o.(CZ): DISA – sustainable green sand moulding/ trajnostno formanje bentonitnih peščenih mešanic
13.30 Conclusion of the Conference With Lunch / Zaključek konference s kosilom
Friday / Petek, 15. 09. 2023
SECTION / SEKCIJA C: Fernand de Magellan Young Lecturers and Researchers / Mladi predavatelji in raziskovalci
10.00 – 10.20 T. ŠVARC1, Ž. JELEN1, P. MAJERIČ1,2, M. ZADRAVEC1, T. GOMBOC1, R. RUDOLF1,2, 1Faculty of Mechanical Engineering of University of Maribor, 2Zlatarna Celje d.o.o., (SI): Recycling of Rapid Antigen Tests: Extraction of Nanogold / Recikliranje hitrih antigenskih testov: ekstrakcija nanozlata
10.20 – 10.40 G. GYARMATI, T. MENDE, University of Miskolc (HU): The Interactions of Grain Refiner Particles and Double Oxide Films in Liquid Aluminum Alloys / Interakcija udrobnilnih sredstev in dvojnih oksidnih plasti v aluminijevi talini
10.40 – 11.00 L. MRKOBRADA, I. JANDRLIĆ, F. KOZINA, T. BRLIĆ, Faculty of Metallurgy of University of Zagreb (CRO): Plastic Instabilities During Processing of AlMg Alloy / Plastične nestabilnosti pri procesiranju zlitine AlMg
13.30 Conclusion of the Conference With Lunch / Zaključek konference s kosilom
Poster Presentations / Plakatne predstavitve
1. T. BALAŠKO, M. VONČINA, J. MEDVED, Faculty of Natural Sciences and Engineering of University of Ljubljana (SI): The Effect of Lanthanum Addition on the Solidification of EN AW-7175 Alloy / Vpliv dodatka lantana na strjevanje zlitine EN AW-7175
2. M. VONČINA1, A. PAVŠIČ1, I. PAULIN2, J. MEDVED1, M. PETRIČ1, 1Faculty of Natural Sciences and Engineering of University of Ljubljana, 2Institute of Metals and Technology, (SI): Assessing the Quality of Grain Refiners / Ocena kakovosti udrobnilnih sredstev
3. I.VASKOVÁ1, P. DELIMANOVÁ1, M. HRUBOVČÁKOVÁ1, L. JANKOVČIN2, 1Technical University of Kosice, 2Handtmann Slovakia, (SK): Some Knowledge of the Development and Use of Molding and Core Mixtures in Foundry Industry / Ugotovitve iz razvoja uporabe peščenih mešanic za forme in jedra v livarski industriji
4. Ł. SZYMAŃSKI1, A. BIGOS2, M. PIESZCZEK1,3, K. ŻAK1, F. WOŹNIAK1, N. SOBCZAK2, J. SOBCZAK1, S. SOBULA1, E. OLEJNIK1,3, P. KURTYKA3, 1AGH University of Science and Technology in Cracow, Faculty of Foundry Engineering, 2Polish Academy of Sciences, Institute of Metallurgy and Materials Science, Cracow, 3Innerco sp. z o.o., Cracow, (PL): Microstructure, Mechanical Properties and Wear Performance of Composite Casting Reinforced by Oxide Ceramic / Mikrostrukture, mehanske lastnosti in obrabna obstojnost kompozitnih ulitkov ojačanih z oksidno keramiko
5. Ł. SZYMAŃSKI1, J. SOBCZAK1, N. SOBCZAK2, A. BIGOS2, T. TOKARSKI4, W. MAZIARZ2, E. OLEJNIK1,3, R. CHULIST2, K. ŻAK1, G. BRUZDA5, 1AGH University of Science and Technology, Faculty of Foundry Engineering, 2Polish Academy of Sciences, Institute of Metallurgy and Materials Science, 3AGH University of Science, Academic Centre of Materials and Nanotechnology, 4INNERCO sp. z o. o., 5Łukasiewicz Research Network – Krakow Institute of Technology, (PL): Meaning of the High-Temperature Wettability in the Aspect of Manufacturing Metal Matrix Composite Reinforced by Ceramic Phases / Pomen visoko temperaturne omočljivosti z vidika izdelave kompozita s kovinsko osnovo ojačanega s keramičnimi fazami
Katharina Faerber: At this point Handtmann is very proactive because we can optimise the design of technical components. However, we are still at a very early stage of this. One of the big challenges is the tight timeline of development. In terms of lightweight construction, optimal industrialisation, and material selection, we choose an approach for our customers that we can optimise quickly and run in parallel.
This is because speed is very important to us. Therefore, our goal is to submit customers an offer within a few weeks. In the last customer order, we were able to save between 25 and 30 percent of the weight of a component. Of course, our customer can also optimise the topology by himself, but it has to be castable too! And this is exactly what we do. Because we can develop the casting process, including the simulation, in parallel with the component design.
Foundry-Planet: What makes you different from other foundries?
Katharina Faerber: Casting is our core business. Continuous development and customer support are also among our priorities. Thereby, we entirely rely on the know-how of our employees, who find sustainable solutions even for complex challenges due to their profound technical knowledge and experience.
"Casting is our core business, but continuous development and customer support are also among our priorities."
Foundry-Planet: How is Handtmann handling the new challenges in the industry?
Katharina Faerber: With the Business Development department and its integrated functions of innovation, product and technology management, we look very closely into what will be necessary in the future and derive the measures to meet these challenges.
This also indicates Stefan's ambition for the globalization of YIZUMI Die Casting. Despite the fact that global uncertainties have been increasing over the last few years, he still sees huge opportunities and growth potential for our company. As he frequently mentions, "To rank among the top-3 globally in the die casting industry is one of YIZUMI’s primary objectives. At present, the annual throughput of die casting machines is over 1,200 sets, which is likely to be further expanded in the future, especially in the area of large structural castings. The production of the large and ultra-large die-casting machines, in the foreseeable future, is an essential battlefield for the industry. Whoever possesses more advanced technologies will have a greater voice in the market. This is reflected not just in revenue, but it is also a strong indicator of the company's overall competitiveness."
For YIZUMI, the objective of "Top-3" is not solely understood in revenue terms, YIZUMI is committed to becoming a top -3 turnkey solution provider worldwide with its advanced technologies and highly competitive manufacturing solutions.
Based on a detailed understanding of "our customer's processes", we are able to develop ever better die casting machines which are easy to use and provide our customers with effective solutions so that they can be competitive in their markets. YIZUMI strives to be more than just a product supplier for the die casting market, we are interested in establishing valuable partnerships with our customers providing them with leading technologies and services in order to generate growth together.
Making full use of our own advantages, and aspire to make YIZUMI a world-class brand
Focusing only on the domestic market in China would certainly constrain our pace of becoming a world-class enterprise. According to YIZUMI’s 2022 annual report, its overseas revenue significantly rose 8.63% year on year in 2022 to 911 million Yuan (about 128 million U.S. dollars). However, the revenue ratio only accounts for 24.76% of the total.
Driven by the rapid development of automotive, telecom and electronics industries, the manufacturing industry is highly globalized and has, due to cost pressures, undergone significant consolidation over the past 20 years.
In this regard, Stefan said that making full use of our own, unique advantages is an important measure for YIZUMI to further expand into global markets. "With the goal of becoming a world-class brand, it is essential to provide professional and competent support for global customers. While our business is growing healthily in the domestic market, we are investing great effort into better positioning ourselves in the international market and increasingly become a valid and attractive alternative compared to other international brands. Our best-cost supply chain and excellent manufacturing capabilities provide us with a highly competitive overall cost structure."
Driven by YIZUMI's globalization strategy, the expansion of overseas factories is proceeding according to plan. In October 2022, YIZUMI's new India Gujarat Factory with a total investment of 100 million Yuan (about 13.8 million U.S. dollars) was officially inaugurated and successfully started operation. It has an annual output capacity of 2,000 units of injection molding machines with maximum clamping forces of 4,000T. This extension of our modern manufacturing base ensures faster machine delivery times for our Indian customers.
YIZUMI's India Gujarat Factory is not only an important international production base and customer service platform, but also an important step of YIZUMI's Glocalization.
Localized operation based on global thinking. YIZUMI extends its production base close to the front line of key markets to establish intimate ties with local customers in order to provide ever better-quality products and services. We believe that this improves our overall competitiveness in local markets and creates crucial new patterns of close collaboration between our overseas subsidiaries and the headquarters in China.
The expansion of YIZUMI's U.S. Ohio Factory has also been on the agenda. In addition, YIZUMI's R&D platform and technical centers in Germany, and technical centers in Vietnam have been established in short succession, signifying YIZUMI's commitment to develop a strong international presence for our customers.
Talent fostering and technology development are the strong driving forces of YUZUMI
Talent fostering and technology development are two critical elements of how we want to develop our business. Providing our customers with leading technology solutions supported by competent customer care services will establish YIZUMI as a global brand and increase our future reach.
YIZUMI has established its R&D center in Germany as early as 2017. In addition, a team of sales engineers and technical customer service experts are based in YIZUMI Germany to cover the European key markets. In terms of research and development, the proximity to the renowned RWTH Aachen University with its leading Institute for Plastics Processing (IKV) has been supporting our efforts in pre-developments of special plastics processing.
The YIZUMI Aachen R&D Center connects and fosters talent in order to execute important technology developments and serves as a platform integrating international and domestic technologies. It is engaged in multi-material light weight applications as well as Mg-Thixomolding processing and is also home to our additive manufacturing team. With this R&D platform, YIZUMI learns and extends technical know-how on manufacturing processes from Europe and advanced European market requirements.
YIZUMI has also established its Global Innovation Center in China. For this, Stefan further expounded on the relationship between customer needs and competent technical services, "Customer needs represent the heart of our development and long-term focus. This is the key to making YIZUMI a global brand. We understand our machines and cell solutions are the 'tools' that our customers use to compete in their markets. It is necessary to accumulate knowledge of customer needs and requirements during the processes of serving customers. With technology platforms like the Global Innovation Center and the Aachen R&D Center, YIZUMI can bring together leading international technology resources and realize the integration of scientific research to drive technology- and industrial innovation. Think Tech Forward and bringing international talent together ensures a better understanding of our customer needs and allows us to provide our customers with better services and technologies."
All these initiatives are based on fostering talents within our organization. YIZUMI strongly focuses on employee development to build a strong network of experienced international experts to ensure continued development. The network provides advice, support, and guidance needed to provide beneficial solutions to our customers. More specialists and cross-functional experts are being cultivated forming the required talent pool to ensure the growth of YIZUMI and our customers.
YIZUMI proudly looks back to very successful 20 years marked by strong growth. Stefan enjoyed being part of the dynamic YIZUMI team over the last four years and is excited and proud to support YIZUMI to continue building up competitive capabilities and grow together with our customers internationally.
Denis Hopp: The entire industry is changing. MEGA or GIGA casting are the topics that are being well discussed at the moment. BMW has developed so-called "injector casting" for e-mobility. There are also improved filling processes. Now, we can see that there is a lot of external input flowing into the foundries, not all of it promising or targeted. We have to keep deciding which technologies are interesting for us and in which direction we want to develop. Until recently, we still had the Lost Foam process. Sometimes you have to abandon old technologies. Recently, I had the opportunity to see the production of the 5th generation of BMW electric motor housings. It is very impressive that the "entire process" at BMW - from the production of the cores to the testing of the castings - is interlinked.
Foundry-Planet: It is exciting to see the variety of ongoing processes. We are in a time of transformation. How do you manage this as a company when the number of castings for ICEs is declining? Are there other technologies that could be an alternative?
Denis Hopp: Melt conditioning is one such possible alternative. We are currently evaluating the different technologies for melt pre-treatment very intensively.
"Even if we "only" stay in our core business, we are looking at a promising future, especially because there are good substitutes in the aluminium sector."
Foundry-Planet: Recently we had an interesting conversation about casting washbasins. Do you think it will go in that direction in the future?
Katharina Faerber: The proportion of aluminium in vehicles will increase. Of course, we look in all product groups of the vehicle, even those that were not accessible to us until now. Because entry barriers can be overcome by developing processes.
Denis Hopp: Basically, other markets can also be interesting for us. One example is the field of communication with the housings for 5G technology. Lightweight construction plays an important role for us not only in automotive construction. After all, there are interesting housings to cast for electromobility in the truck sector as well.
Of course, customers who buy a large number of units are the most interesting for us. But even if we "only" stay in our core business, we are looking at a promising future, especially because there are good substitutes for e-mobility in the aluminium sector, compared to iron casting.
Foundry-Planet: This shows that your company is on the right way by entering as Tier ONE in MEGA casting. With the new plant, the first step has already been taken. Does that mean that many more steps will follow?
Katharina Faerber: Handtmann will continuously invest in the further development of megacasting as well as the processes that go beyond it. The mega-casting plant will be set up in Biberach at the beginning of 2024. We welcome you to visit the plant!
Foundry-Planet: Thank you very much, it’s a pleasure for us to come! Last question: The competition between die casting and gravity die casting: How do you deal with that?
Denis Hopp: We handle it calmly because we serve different product groups. In my opinion, there is no internal competition. When necessary, we choose the method that is better for us.
Katharina Faerber: Gravity die casting can be an alternative, but we are primarily die casters.
Foundry-Planet: Thank you for the interview!
The interview was conducted by Thomas Fritsch, CEO, Foundry-Planet and Diana Engelmann, International Editor, also Foundry-Planet.
Information about Handtmann Metallgusswerk GmbH & Co. KG
- Founded: 1873
- Headquarter: Biberach an der Riß
- 4,300 employees worldwide (stand 2022)
- 1.1 billion euros turnover (stand 2022), 597 million euros in light metal casting
- 6 business divisions (light metal casting, filling and portioning systems, plant technology, plastics technology, systems technology, e-solutions)
Situated close to the eastern coast of India is Baettr's newest foundry, Baettr Chennai. The foundry is a flagship in terms of energy usage, logistics and sustainability. Here, wind turbine components will be casted, machined, painted and prepared for wind turbine OEM's in India and globally, giving Baettr's partners a strategic advantage through close proximity to the Asian market as well as overseas.
Originally started in 2020, the first components was casted at Baettr Chennai in Q1 2022.
From the outset, the foundry will have the capability to process items up to 35 ton. Assessment for increasing capability in later phases is ongoing, as to best be able to serve the market. In terms of annual production capacity, Baettr Chennai is designed to be at 50,000 ton in 2025.
Now Baettr Chennai has received full approval from Vestas after the Supplier Business Assessment Audit as confirmed by CEO Peter Pallishøj.
CO2 emissions of primary production of
aluminium and steel.
Copper recycling and raffination has the highest potential for CO2 emissions (Fig. 2). Per t of liquid copper produced, the CO2 emissions can vary between 740 and 1,900 kgCO2. Modern and highly efficient copper producers can drop CO2 emissions to 740 kgCO2 per t of copper. Iron production in a cupola furnace, which is a shaft furnace with a large heat exchange section, generates 300 to 600 kgCO2 per t of liquid iron. Here again, very modern, and efficient plants with high are preheating and oxygen enrichment can achieve lower CO2 emissions. Efficient melting of aluminium in a rotary furnace can bring the CO2 emissions down to 120 kgCO2 per t of aluminium.
The exhibition covers an exhibition area of over 80,000 square meters, with a total of 6 themed pavilions and over 100 supporting events, attracting 127,616 professional visitors from more than 30 countries and regions. As the first regular event in the post-pandemic era, METAL CHINA once again showcases its industry influences with its 36-year history. The exhibition hall is filled with joyful and fruitful atmosphere, most of the exhibitors and visitors said, “there are many visitors visiting our booth, more than expected", “we have made several deals at this exhibition”, “face-to-face communication is really exciting”, "there are so many international buyers, we have established contacts and preliminary intentions”, “it’s a fantastic event with well-organization and round services”, "the exhibition is burst of vitality", "it’s a worthwhile trip", “we are looking forward to the next METAL CHINA”, etc..
"The target of the project was the development of a tool that enables SMEs an easy entry into digitalisation and Industry 4.0 whereby the added value is immediately recognisable."- Dr.-Ing. Eric Riedel
"The target of the project was to develop a tool that enables SMEs an easy entry into digitalisation and Industry 4.0 whereby the added value is immediately recognisable and can be easily integrated into the existing process. In my opinion, the Pouring Ladle 4.0 reflects exactly that," states Riedel about the motivation behind his project. In application, the Pouring Ladle 4.0 combines several useful features such as real-time transmission of measurement data, an interface with miniature plug connection and thus the use of established thermocouples, inductive charging with rechargeable battery and a modular design with replaceable wear module.
Conclusion: According to Riedel, the Pouring Ladle 4.0 shows that Industry 4.0 and manual casting production are very compatible with each other, whereby the human resource is well integrated in this development.
GF Piping Systems
The division saw lower demand in its Building Technology and Gas Utility business, however, its presence in growth markets and segments, such as high-end microelectronics production and process automation for water reclamation and treatment, made up for it. Sales amounted to CHF 1'065 million in the first half of 2023 (2022: CHF 1'094 million), representing an organic increase of 4.2%. The operating profit came in at CHF 141 million (2022: CHF 158 million), for an EBIT margin of 13.2% (2022: 14.4%).
In June, GF Piping Systems announced it had received Intel’s EPIC Distinguished Supplier Award, a milestone that highlights the division's customer focus and commitment to excellence, and rewards a consistent level of strong performance.
With its state-of-the-art manufacturing layout for the production of process automation applications, its clean room for pre-fabrication and the modern training center, the newly inaugurated site in Yangzhou (China) is ready to meet the increasing customer demand for sustainable solutions.
In July 2023, GF Piping Systems received the EcoVadis gold medal for its sustainability performance. This award positions the division among the top 5% of companies assessed worldwide.
GF Casting Solutions
Growth in sustainable mobility reached an all-time high, with 86% of high-pressure die casting lifetime order intake related to e-vehicles. Sales reached CHF 471 million (2022: CHF 449 million), an organic increase of 20.0%, due in part to strong demand for e-vehicles. Operating profit increased substantially to CHF 35 million (2022: CHF 14 million), for an EBIT margin of 7.5% compared with 3.2% in 2022. The division is increasingly recognized for its innovation strength and capabilities to produce mega castings, which are a key differentiator in the production and assembly of e-vehicles. The ramp-up of the factory in Shenyang (China) is also progressing according to plan.
GF Casting Solutions earned its first EcoVadis gold medal for its sustainability performance in March 2023. This award positions the division among the top 4% of companies in the "Casting of Metals Industry" segment.
GF Machining Solutions
Considering the current demanding macroeconomic environment, GF Machining Solutions achieved a good order intake of CHF 461 million (2022: CHF 478 million), resulting in a book-to-bill ratio of 1.1. Sales reached CHF 426 million in the first half of this year (2022: CHF 431 million), organically up 3.7%, thanks to a rebound in the aerospace sector, where global order intake returned to pre-COVID-19 levels. Operating profit reached CHF 20 million (2022: CHF 17 million), leading to an EBIT margin of 4.7% (2022: 4.0%), supported by a strong MedTech segment and a high share of innovative solutions in the EDM technology.
The division continues to be an industrial technology leader, pursuing its strategy to strengthen customer experience and service offerings, including digital services.
GF Machining Solutions launched new high-performance laser machines for applications in several segments. One of these applications is anti-scratch surfaces on plastic components, where laser textured molds make it possible to reduce plastic coating chemicals, a big step in the sustainability journey of its customers.
Tender offer launched to acquire leading Finnish company Uponor
On 12 June 2023, GF announced its voluntary recommended cash tender offer to acquire the Finnish company Uponor, which, if successful, will pave the way for GF to become a global leader in the Water and Flow Solutions business, and increase its resilience and growth prospects. This is a transformative step for GF, which, upon successful completion, will accelerate the execution of its Strategy 2025 to drive profitable growth. The transaction is expected to close in Q4 2023.
Outlook for the full year 2023
The present volatile environment is likely to persist in the short term, but with a different situation per market segment. GF Piping Systems is dealing with a subdued worldwide construction industry, and gas utilities in Europe and Asia are facing headwinds. At the same time, the industrial segments are continuing to enjoy good momentum globally. GF Casting Solutions' good position in the e-vehicle and high-end segments is expected to support its business, also in the second half of the year. GF Machining Solutions faces subdued ICT markets, especially in China, but MedTech and aerospace order intakes are solid.
Overall, GF is set to benefit from strong positions in resilient market segments. In particular, the sustainability needs of our customers continue to offer excellent long-term business opportunities. Barring unforeseen circumstances, for the full year 2023 GF expects to achieve organic sales growth in line with its Strategy 2025 and an operating profitability within the Strategy 2025 corridor (EBIT margin 9-11%).
GF uses certain key figures to measure its performance that are not defined by Swiss GAAP FER. Comparability to similar figures presented by other companies might therefore be limited. Additional information on these key figures can be found at www.georgfischer.com/en/investors/alternative-performance-measures.html.
In order to achieve the "mutual sanctification" of exhibitors and visitors, METAL CHINA 2023 is consisted of 6 themed halls of advanced foundry equipment, green raw and auxiliary materials, high-end casting, featuring in investment casting area, wear-resistant parts for mining and metallurgical heavy machinery and engineering machinery, industry cluster area, art casting area, etc.; at the same time, there are Peru and Kenya pavilion shows the interaction of foundry and other elements. New technologies, products, and purchase orders have built a bridge for the world foundry industrial chain.
During the four exhibition days, more than 100 exciting events were staged, focusing on the hot topic of high-quality development, including new product launches, theme forums, sourcing fair, strategic signing activities, and award ceremonies; Leading enterprises and SMEs present a vibrant development trend; There is a whole industrial chain, from high-end castings to intelligent equipment, and green advanced materials. New products, technologies, solutions, and trends are intertwined here... joyful and thoughtful discussions, innovative solutions are blooming, showing a thriving industry trend.
expanded its scale and business. The company regards METAL CHINA as an important platform for brand and product promotion, and business negotiation. In 2023, it coincided with the independence of Calderys from France's IMERYS Group and belongs to Platinum Company. After, it was strategically integrated with Harbison Walker International (HWI). Calderys China presented a new image at the expo. Calderys China and S&B Bentonite (Chaoyang) jointly held the "Calderys Technology Day" and presented One Stop Shop Solution for foundry industry. All activities ended with full success, and the exhibition yielded fruitful results. We hope to engage in more exchanges and cooperation with China Foundry Association in the future, using high-quality refractory materials and bentonite products and solutions to support the high-quality development of China's foundry industry.--Calderys China Co., Ltd. and S&B Bentonite (Chaoyang) Co., Ltd.
This year is the 21st China International Foundry Expo, and also the 21st time that Sinto Group has participated in. The expo was fueled with more professionalism: the exhibits portfolio is rich, the international level of visitors has been significantly improved, and it really reflects its position as a “wind vane” of the industry. Through participating in the exhibition, we not only showcase the advanced foundry equipment, processes, and high-quality service concepts, but also reach to our global customers. We hope that under the leadership of China Foundry Association, METAL CHINA will become better and better in the future. At the same time, we also wish the Chinese foundry industry prosperous and prosperity.--Qingdao Sinto Machinery Co., Ltd.
- China International Foundry Expo (METAL CHINA), created by China Foundry Association, has a development history of 37 years and is at a world-class level in terms of exhibition scale, industry status, and internationalism. CBMM and CITIC Metal made their debut in 2023. Although it was their first participation, the results exceeded expectations: we built relationships with more Chinese enterprises, and saw more opportunities. METAL CHINA provides an effective platform for our company to explore the Chinese market. The Chinese foundry market is vast, and is also the prospects for cooperation between China and Brazil. We attach great importance to Exhibitor comments: Wind vane, barometer and touchstone
We showcased high-end wear-resistant casting products at this exhibition, attracting the attention of many domestic and foreign audiences on site. We had a different feeling about this year's exhibition from previous ones, it was held in Tianjin for the first time, and as a local enterprise, we were extremely proud to participate and showcase the strength of Tianjin enterprises at our doorstep; In addition, we not only received old friends, but also gained many new customers. From the first day of the exhibition, our booth reception has been very busy, and multiple cooperation intentions have been reached at the exhibition site. Thanks for the exhibition that high-quality visitors have brought tangible results to us. Looking forward to the China International Foundry Expo becoming better and better, let's work together to promote the high-quality development of China's casting industry.--Tianjin Lixinsheng New Material Technology Co., Ltd.
In the decades since entering Chinese market, Calderys has continuously the Chinese market and hope to establish cooperation with more Chinese enterprises through the high-end platform in the future, achieve mutual benefit with complementary advantages. We look forward to meeting you at the next exhibition.--CBMM
METAL CHINA is the largest and most influential foundry industry exhibition in China, it comprehensively showcases the development level of China's high-end castings, reflects the overall strength of China's foundry industry, and proves to the world that China's casting industry has grown from big to strong. At the exhibition, our company has received high attention and praise from numerous domestic and foreign visitors. Among them, our "HSTD144/294/710EF bearing seat" has won the "Gold Award for First-class Casting". As an enterprise with a history of 120 years in casting production, our company has participated in METAL CHINA for consecutive years, and the Expo is our preferred show platform. By participating in the Expo, we have demonstrated our corporate brand strength, enhanced our confidence in development, and strengthened the company's confidence and determination to continuously improve its product quality and help China Foundry go global.--Yantai Moon Intelligent
Machinery Technology Co.,Ltd
- High praise from international buyers
We got a lot of information and many supplier for our business from METAL CHINA 2023. There are a lot of factories and agents with steel raw materials we are finding. Hoping to join in the next event.--Thailand Visitors
We have achieved our goals as expected. China has developed exceptionally rapid in recent years. During the last three years, although there were signs of decline in the manufacturing industry, it provided more space for high-end enterprises to rise through industry integration. Technically, the independently developed products in China’s foundry industry have emerged at a fast pace and low cost, which has better stabilized China's position as a leading foundry nation. At the same time, the strong demand for new products and processes from various foundry enterprises has also attracted more attention of the world to the Chinese market.--Japan Visitors
It was good. We achieved all the goals we had set out to do. Overall an eye opening experience I think. We're in the process of negotiating some deals, mostly for raw materials, but there's some for machinery as well. Thank you for the top notch service.--Vietnam Buyers
The visit to METAL CHINA 2023 in Tianjin was very good and unexpected! We were very excited and also shocked at the rapid development of China’s foundry industry in recent years. We have got a lot of information, learned about the latest development of the foundry industry, and achieved multiple purchasing intentions. It’s really a great trip!--Belarus Buyers
We were very excited to participate in Metal China again. At the exhibition, we have met old and new friends after a long time, we have learned a lot from the numerous new products, technologies and solutions as well. Wish China’s foundry industry a prosperous development and looking forward to the next year.--Malaysia Buyers
Larger scale, Higher level, Higher quality
A brand new METAL CHINA will be staged in National Exhibition and Convention Center (Shanghai) again (held in Shanghai in even years), from July 4-7, 2024. A larger scale, high level industry event, covering foundry, diecasting, metalforming, heat treatment, surface engineering, welding, jointly created by 5 industry associations, will grandly display with nearly 1500 exhibitors and 150 supporting programs, which will build a high-quality development industrial chain of the foundry industry. Looking forward to your continued attention and participation.
For more information, please visit https://www.expochina.cn/en/index or email to Maggie Li by limengmeng(at)foundry.com.cn
Even for recycling of metals, the required energy to heat and to melt the metal can be very different depending upon process conditions and process control. The coke rate of a cupola furnace operation determines to a large extent of the CO2 emissions per t of liquid iron (Fig. 3). To lower the coke rate, a cupola process has been the objective of the cupola operators for more than 200 years. The coke rate of a cupola can be lowered with hot blast operation and combination of oxygen lancing.
Aluminium recycling can be very efficient in rotary furnaces and reverb furnaces. Subject to air preheating level, process tightness and oxygen usage, the overall thermal efficiency (Fig. 4) can vary. It can be noted that preheated combustion air to 1000°C and above can deliver similar results than oxy-fuel combustion. The thermal efficiencies are above 50 % and the CO2 emissions per t of liquid metal are slightly above 100 kg CO2. In the middle section of the graphic with air preheating temperatures of 200 to 400°C, selective oxygen use can be added for further energy savings and CO2 reductions.
Feedstock materials with organics, typically 0.5 to 3 mass. -% can be added to improve the energy balance and fossil fuel savings when the organics are gasified and combusted in the melting chamber right after charging.
The minimum CO2 emission limit can be seen at about 100 kg CO2 per t of liquid aluminium when firing natural gas. It can only be further reduced by using hydrogen.
If it is considered that today’s typical aluminium melting process generates about 200 kg CO2 (at ca. 940 kWh/tAL specific energy use) per t of liquid aluminium, then the requested 80% CO2 reduction would be a reduction of 160 kg CO2. With a remaining CO2 generation of 40 kg CO2 per t of liquid aluminium. A change like this cannot be done with technical improvements and process tightening alone. A request like this does require the use of a fuel mixture of natural gas and hydrogen or electrical heating with plasma burners or induction heating with electricity from renewable climate neutral power sources (wind, hydro and solar).
This example would lead to a fuel blend of 7 vol.-% natural gas and 93 vol.% hydrogen. For a modification this kind, new combustion equipment would be required that is certified and safe for hydrogen service and a burner technology that would deliver the desired melting results with a hydrogen flame. This example also emphasizes that a fuel blend of 90 vol.-% natural gas and 10 vol.-% hydrogen will not give the demanded CO2 reductions of 80%.
Alternative Fuels
Ammonia, methanol, and hydrogen are potential alternative fuels for the metals producing industry. When hydrogen is combusted, no CO2 is generated. Hydrogen and oxygen burn to water vapor (H2O). H2O is not considered a greenhouse gas and is not critical for the roadmap 2050 [1]. Hydrogen is not an available resource on our planet. Hydrogen must be produced, and the production is energy intense. The favored method to produce green hydrogen is from electrolysis with electrical power from renewable energies like wind, solar or hydro (Fig. 5).
Hydrogen is a gas with low density and consequently difficult to store. Potential ways to store and transport hydrogen would be in liquid form of ammonia and methanol. Green hydrogen would be the base component to synthetically produce green ammonia and green methanol. Methanol is a liquid and ammonia is a liquid too, when stored under pressure.
Biogas can offer another alternative if it can be blended into the natural gas grid or the biogas plant is operated near a metals production plant. Biogas has higher heating value as compared to hydrogen and about half the heating value of natural gas (at CO2 conc. of 46 vol.-%).
The properties of here discussed alternative fuels are very different from each other (Tab. 1) and combustion equipment, combustion controls, ignition and burner geometries must be adjusted to give desired results for melting process conditions.
When hydrogen cost could be reduced to about 2 Euro/kg, it is believed that it can be used in industry scale. Today, hydrogen availability is too low, and cost are too high to realistically start without funding. Green hydrogen cost is 3 to 4 times higher than hoped for. Current energy crises and dependence from fossil fuels add fluctuations and uncertainties.
Next Generation Burner Technology
Hydrogen is definitely not a new medium for the industrial gas industry. Hydrogen has been produced and handled for decades. In the past, hydrogen cost was simply too high to be combusted for metals production processes when natural gas was available and affordable. Valve stations and burners for hydrogen service can be engineered in a safe and reliable way.
All fuels in Table 1 will burn and can potentially be used to melt and heat metals, heat ladles and provide process energy for metals production. Very little experience exists what impact the alternative fuels will have on the specific process in terms of: NOx emissions, heat transfer, flame coverage, refractory life, water condensation, metal quality and cost. In this respect, a stepwise approach to climate neutral fuel mixtures can be beneficial. During this path, the burner geometry and oxygen usage pattern might be altered to achieve best results.
Due to increased adiabatic flame temperature of hydrogen, it is expected that NOx emissions might increase. Staged combustion will be possible with hydrogen as a main fuel component and will have a similar NOx lowering effect as with natural gas combustion systems.
Multi fuel burners can burn different fuels in parallel, or fuel blends can be fired in single fuel burners. To avoid flame, blow off and unsafe situations at single fuel burners and different fuel blends, the burners must be re-engineered.
Safety
Safety is always the highest priority. A fuel transition and climate protection can only be successful when done safely. Hydrogen is a gas with low ignition energy and wide ignition limits, this can make hydrogen the potentially explosive cause when mixed with air. Hydrogen molecules are small and require special engineering design methods to make flow panels safe. Increased water vapor content and higher dewpoints can lead to more condensation on the flue gas system and around the furnace. Hot steam jets from furnace and ducts can be a hazard for furnace operators. Condensed water can cause steam explosions when brought together with molten metal.
On a national and international level, safety standards and guidelines for the handling and combustion of mainly hydrogen containing fuels need to be developed.
Conclusions
It is possible to reduce dramatically CO2 emissions from metal production processes with the help of alternative fuels like hydrogen, biogas, ammonia, and methanol. It is expected and hoped that this effort will reduce climate change in way that global catastrophes are largely avoided. The changes to metal production processes will be big. Combustion technology, burner design, process steps and flue gas systems need to undergo modifications to be able to generate 80% less CO2 emissions.
Not much is known about how melting processes and metal quality are affected by this change. Extensive work is required to reduce the risk that can be taken here.
Meanwhile, and until green fuels are available, stepwise fuel changes can help to better learn about the implications that this energy switch will bring. These changes can be in any kind to support energy utilization and reduction of CO2 emissions.
Since nitrogen is not actively involved in the combustion process, it acts as a coolant and takes away heat from the process. It makes sense to reduce the nitrogen load of combustion processes by using oxygen enrichment in any kind. Oxygen use is also possible at existing furnaces and combustion systems and will result in energy savings and reduced CO2 emissions.
Combustion air pre-heating and oxygen use can bridge the time until green fuels are available on industrial scale.
References
[1] Roadmap 2050 – Technical Analysis, Volume 1, April 2010
[2] Klimaschutzplan 2050, BMUB, Berlin, November 2016
In 2022, China accounted for a 39.1% revenue share and 55.4% shipment share of the global industrial robot market. Interact Analysis forecasts that the Chinese market will account for over 60% of industrial robot unit shipments from 2024. The EMEA market for industrial robots was the second largest in the world accounting for 14.8% of total shipments in 2022. The Russia-Ukraine conflict is still a significant threat to Eurozone growth prospects not only because of energy price increases but also because it pushes down business confidence, which could affect employment and investment decisions. The American market for industrial robots was estimated to be worth $2.8Bn in 2022, accounting for 19.8% of global revenues, with 55,268 units shipped.
Maya Xiao, Research Manager at Interact Analysis comments, “Interestingly, in 2022 the average selling price of industrial robots increased for the first time in the last 10 years, as a result of raw material cost, component shortages and supply chain disruptions. Despite this, we forecast that average prices will decrease over the next 5 years.
“The increased demand for industrial robots from the material handling and welding sectors has had, and will continue to have, an impact on average selling prices. As a result of this, demand for heavy-duty models has once again increased, which has altered the payload distribution of the robot market. However, overall, we expect to see a 3% annual decline in prices over the next 5 years.”
About the Report:
This report outlines the scope and content of the market report providing insight and analysis into the industrial robot market. The research covers, among others, market size and forecast data for industrial robots with detailed segmentations both revenue and shipment terms, as well as 5-year forecasts out to 2027.
About Interact Analysis
With over 200 years of combined experience, Interact Analysis is the market intelligence authority for global supply chain automation. Our research covers the entire automation value chain – from the technology used to automate factory production, through inventory storage and distribution channels, to the transportation of the finished goods. The world’s leading companies trust us to surface robust insights and opportunities for technology-driven growth. To learn more, visit www.InteractAnalysis.com
The power of collaboration
Together with partners, Bühler rethinks, designs, and commissions entire solutions and can therefore offer process solutions from ingot to the body shop. At the event in Austria in June, partners involved in the process will present their area of expertise within the die-casting cell. Visitors have the chance to gain insights into die design, efficient melting of aluminum, tempering and spraying of the die, and much more. As the core of the cell, the Bühler Carat series enables parts to be cast at the highest quality.
Bühler Advanced Materials – partner for the automotive industry
Bühler’s Advanced Materials business not only provides die-casting solutions for the automotive industry but also actively engages in the fields of battery production and sensor coating, thereby offering key solutions for the vehicle of the future. The Grinding & Dispersing business is heavily involved in the production of battery slurries solutions for electric cars. Bühler Leybold Optics is driving solutions for advanced driver assistance systems (ADAS) coatings. "With the broad portfolio in our Advanced Materials business, we offer innovative and state-of-the-art solutions for the automotive industry," says Marcel Natterer, CEO Advanced Materials at Bühler.
2. Zinc casting is suitable for countless applications, from simple window fittings to complex electronic components and automotive components to spectacle cases. To which industry do your biggest customers belong? The die cast parts are mainly supplied to the electrical industry and drive technology. Brackets and fittings for doors or windows are also produced for the fastening industry. 60 - 70 % of these die cast parts are exported and approx. 30 % are produced for Swiss customers.
3. How has your industry and applications developed in recent years?
Many die casting foundries are following the trend and investing in Megacasting, the joining of several components into one die cast part. It has the potential to revolutionize the manufacturing process of automobiles. Since Macrocast specializes in small-series parts and produces small parts, Megacasting is not done. There are no such changes coming in the casting process for small parts. The more cavities a mould has, the greater the challenge to ensure that all castings in the same production cycle are cast in perfect and equal quality.
However, there is a clear trend towards connectivity. Connecting the temperature control unit to the machine control system simplifies the production process significantly and is indispensable in terms of quality assurance. The temperature controller ensures that the die cast parts are produced without quality problems.
4. In what way do Tool-Temp units simplify the production process in your die casting foundry?
The greatest risk in the production of die cast parts is material doubling, which can occur due to cold fronts during casting (too low casting speed leads to premature solidification). Especially with thin-walled castings, material doubling is particularly visible and cannot be accepted. The solidification temperature of zinc is 387 °C and therefore, Macrocast relies on Tool-Temp oil tempering units, by controlling at high temperatures.
Our goal is the continuous optimization of cycle times, and this is achieved by using the Tool-Temp oil temperature control units TT-248 (up to max. 200 °C), TT-288 / MP988 (up to max. 250 °C).
5. How many hours are the Tool-Temp units in use every day?
We use the units for 13 hours per day (at the end of the shift the units are switched off), but they can easily be used in 24/7 operation.
6. We are very grateful for our long-standing good business relationship. What brought you to Tool-Temp years ago?
More than 6 years ago, employees came across Tool-Temp through internet research. Since the focus was on independence, individual solutions, quick communication channels and fast availability of equipment and spare parts, it quickly became clear that Tool-Temp would become the business partner.
7. What are your experiences with the Tool-Temp units?
The temperature control units are very reliable, this is proven by their control accuracy. They easily withstand the rough everyday conditions in die casting.
With very small cooling bore cross-sections, there is the difficulty of heat dissipation, and this can be easily compensated for by higher tool temperatures. Macrocast relies on the robust Tool-Temp oil temperature control units. The uncomplicated system design makes the units easy to operate
8. Are you satisfied with the performance of the units and the Tool-Temp service?
We appreciate the very short reaction times and solutions from Tool-Temp-After-Sales and are pleased to confirm that we have not had any production downtimes with the use of Tool-Temp temperature control units.
We are very satisfied with the unit’s performance, consequently, when we wanted to modernize our cooling system a year ago, it was also clear to us that Tool-Temp would offer a solution tailored to our requirements. Since then, the TT-216'000 cooling unit has provided the cooling water supply for the entire die casting system and all temperature control units.
Manager of the die casting foundry Macrocast GmbH
CEO Advanced Materials, Member of the Executive Board at Bühler Group, Ing. Franz Füreder | Vice President BU Automotive bei Engel Austria GmbH, Jochen Wallmüller | Sales Director Automotive bei ENGEL AUSTRIA GmbH
By exploiting the synergies in the different core competencies of both companies, new solutions in die casting are thus always possible. "The implementation of the clamping units for the currently largest machines in Bühler's portfolio - the Bühler Carat 920, which was built in our ENGEL plant in Asia, and the Bühler Carat 840 in St. Valentin - are milestones for us of which we are very proud," Stefan Engleder and Franz Füreder, Head of the Automotive Business Unit at ENGEL, emphasize the importance of the cooperation with Bühler.
Cornel Mendler, Managing Director Die Casting at Bühler, also agrees. For him, the joint presentation of the two companies is a strong signal. "The cooperation with ENGEL and our joint pursuit of innovative solutions for the future can create great and powerful things - the Carat 840 is a symbol of this."
At the event in St. Valentin (Linz), Austria, Bühler showcases its megacasting technology with 8,400 tons locking force to international representatives of the die-casting and automotive industry for the first time in Europe. With a height of 7.6 meters and a floor area of around 160 square meters, the Carat 840 can inject over 200 kilograms of liquid aluminum into a die within milliseconds.
Reducing complexity in automotive manufacturing
The production of larger and more complex parts is considered groundbreaking by many car manufacturers who are moving in this direction or thinking about adopting that solution. Megacastings reduce complexity in production by enabling between 70 to 100 parts to be replaced by a single die-cast part. These single-piece castings will generally be produced close to the automotive assembly line, which allows for better integration and reduced transport.
“The future of the automotive market is being shaped by various forces. The main factors today are reducing complexity, increasing productivity, and improving sustainability,” says Cornel Mendler, Managing Director Die Casting at Bühler Group. “Our event is a unique chance for our customers and partners to experience the innovative technology behind megacasting and network with members of the industry from across the entire value chain.”
Martin Lagler, Director Global Product Management & Marketing Die Casting at Bühler Group, goes further and says: "By stepping into this market and supplying OEMs directly, our presence in the automotive industry has become stronger. It is therefore important for us to show the industry what we can offer and how we can work together on future-proof solutions for lighter and more sustainable vehicles."
Sustainability as a driver for aluminum die casting
Apart from the reduction in complexity, aluminum castings have the potential to drastically reduce CO2e emissions in manufacturing, with fewer processing steps and especially when using renewable energy or electric melting. CO2e per part is also reduced by minimizing waste and using low CO2e aluminum alloys. The aluminum that goes into overflows and runners can be remelted directly and reused in the die-casting cell, thereby avoiding transport for recycling.
Our internal studies show that compared to benchmark emissions today, megacasting offers the potential to reduce CO2e emissions by 70%. This can be achieved by using aluminum alloys with low CO2e footprint, avoiding fossil fuels for melting, and powering all operations with renewable electricity. This allows car manufacturers to reduce the carbon footprint of their products," explains Martin Lagler, Global Director Product Management & Marketing Die Casting at Bühler Group.
Award for the cast part for the best integration of functions
Award for the best substitution for a different manufacturing procedure
Award for the best lightweight construction solution
In 2020 the premium German automaker asked Loramendi to develop a core making installation to fill the existing gap for massive inorganic core production facilities for their e-housing. The project had a very demanding lead time and high output targets that could not be met with the customer's existing machines. The new core making line includes a sand plant and a fully automated 100L machine to produce the massive inorganic cores (up to 70 kg per shot).
After having successfully achieved the output rates and lead times of the first joint project for these housings, BMW decided to invest in a new core shop dedicated entirely to producing the e-motor housings: this new installation consists of a sand plant, one 100L core making machine (to produce the previously mentioned massive cores) and one 25L core making machine to produce the technically demanding water-jacket cores for this e-motor housing. During the development of the equipment, BMW and Loramendi again cooperated closely from the very from the very beginning of the project, as production rates had to be further increased for this new core manufacturing plant. As a result of this outstanding cooperation, it was possible to achieve the necessary key performance indicators, which has further cemented the long-standing relationship between BMW Landshut and Loramendi.
Based on this mutual trust and cooperation, Loramendi is now working on three additional core shooting machines for BMW, which include three sand plants, three 100L core shooting machines, and one 25L core shooting machine. One of these 100L machines will be shown at Loramendi’s stand at GIFA 2023 in Düsseldorf. If you are interested in learning more about our core shooting technology and this amazing success story, do not hesitate to visit us during GIFA 2023 at the Loramendi & Aurrenak stand E26 – E34 in hall 16. Our on-site technicians will be happy to answer any questions you might have related to this project. For interview requests, comments or suggestions relating to core shooting technology, please contact: info(at)loramendi.com
So he calls for more investment in talents and competence. Italy was a foundry Disneyland for classic castings for the automotive industry and now they must find alternatives.
GIFA is the right time for exchange and face to face meetings and the Italian supplier industry is expecting and hosting visitors at GIFA in hall 11 and 16 at the Piazza Italia.
Get an impression of Italian competence and hospitality and listen to the exciting podcast with Riccardo Ferrario (11 min.), about the foundry industry and also about the future of giga castings.
Founded in 2013, the company has developed a unique sand regeneration technology that enables waste sand to be cleaned and reused. Resandi's technology enables foundries to recycle almost 100% of the sand used in production. The solution reduces the environmental footprint of virgin sand use and the CO2 emissions from sand use. At the same time, it brings significant savings for foundry customers.
Resandi's sand regeneration technology has proven to be a successful solution and the company has already implemented several commercial projects with Finnish foundries. The company is also expanding into international markets. In March 2023, Resand started its first project in Germany with Siempelkamp, the global market leader in hand-casting solutions.
The company's new name, << Resand >>, was registered in the Commercial Register and came into effect on 08.06.2023.
Resand Oy
As early as 1985, Loramendi recognized the special importance of the German foundry market with its long-standing tradition, high production quality and marked technical expertise, consequently it founded a subsidiary in Germany. Since then, the company, together with its technology-oriented customers, has been spearheading new developments in the field of core technology. The best recent examples being the production of inorganic cores; the production of massive cores in the e-mobility sector; and currently the successful industrialization of 3D printed sand cores. We will be sharing these truly pioneering achievements with you at GIFA.
Such successes are only possible with the cooperation of longtime customers and close partners. So together we have prepared a great informative conference program for this year’s GIFA, which will be presented in our Knowledge Plaza for anyone who is interested.
This year we are focusing on sustainability, digitalization and prototyping, and especially on merger of Loramendi & Aurrenak. Together we have built a unique combination, allowing us to offer you bright solutions for your foundry and to continue providing real, groundbreaking services in the field of casting.
I am personally very proud to be co-responsible for shaping this special year together with the whole Loramendi & Aurrenak family. There is nothing more natural for us than to share our joy, our celebration and also our latest developments with our long-standing customers, our partners and all interested parties. So on this special occasion we invite everyone to visit our stand E26-E34 in hall 16 at GIFA.
Dr. Ing. Oliver Vogt
General Manager
Germany & Central Europe
Our mold release agents for structural castings, made of naturally hard and self-hardening alloys, have already proven themselves many times in practice, both for conventional structural castings and for new projects on so-called Gigacasting machines.
A standardized test specimen (bending bar)exhibit a cold strength of 375 - 400 N/cm2 and a moisture content (600 °C) of about 0.20 % one hour after core production, regardless of the promoter generation used . For the 4th generation of INOTEC promoters, the strength already decreases continuously at the beginning of the storage process. The half-life of the cold strength is already reached after a storage time of 8 hours. At the same time, a strong increase in the moisture content of the sand core can be seen, amounting to 0.40 % after a storage period of 8 hours. In contrast, the 6th generation promoter shows a constant strength level up to a storage time of 10 hours and a reduced moisture absorption of 0.30%. Only in the further course of the storage period a decrease in strength becomes apparent. Nevertheless the strength retention within the storage period of 24 h is approx. 82 % of the cold strength. The moisture content determined at 600 °C is then 0.35 %. Both parameters demonstrate the improved moisture stability of the 6th promoter generation. In addition to this improved moisture stability during core storage, the use of the 6th generation promoter also leads to improved process stability during raw part machining. Figure 2 shows the shake out property of a standardized test specimen (bending bar)based on the 4th and 6th promoter generation when the raw castings are stored at different humidity levels. The specimens were thermally stressed at 650 °C, stored accordingly at different climatic conditions and the shake out property was determined after mechanicalimpact . The shake out behavior of inorganically bonded sand cores based on the 4th promoter generation is negatively affected with increasing storage time and higher absolute humidity. In contrast, the shake out property of inorganic-bound sand cores based on the 6th generation promoter remains constant.
"We must continue to develop in order to secure the future of mechanical engineering", Roland Hübner, CEO of the Kempten iron foundry.
From the foundry side, the panel includes: Roland Hübner, Member of the Board of the Kempten Iron Foundry; Foundry Manager Michael Windl, Sales Manager Manfred Szymanski, Production Planning Manager Alexander Kraus and IT Manager Jean-Pierre Hacquin. The discussion was led by Thomas Fritsch, CEO of Foundry-Planet (www.foundry-planet.com), as the accompanying journalist.
The groundbreaking questions are, at what stage of development is the foundry industry with regard to digitalisation and AI and how innovative and progress-oriented is this industry. "Especially for the medium-sized industry with its very specific framework conditions, we as a university institute have to develop digitisation in a way that is application-oriented, tangible and comprehensible. This is always a joint task, to stay on the ball and continue to develop in order to create resilient building blocks for securing the future of foundries," says Hartmann.
Where does the motivation for cooperation come from?
But where does the motivation for the cooperation between the university and the iron foundry come from? "The motivation came because we wanted to be part of this development process," explains Hartmann. "Our goal was to have a good basis for the university's research and development. We have a good network with funding associations and industry. But you only have that if you do reasonable work. The fact that we help the foundry in the data transformation process is important - in all the institute's projects," says Hartmann.
The FISI – European Foundry Industry Sentiment Indicator – is the earliest available composite indicator providing information on the European foundry industry performance. It is published by CAEF the European Foundry Association every month and is based on survey responses of the European foundry industry. The CAEF members are asked to give their assessment of the current business situation in the foundry sector and their expectations for the next six months.
The BCI – Business Climate Indicator – is an indicator published by the European Commission. The BCI evaluates development conditions of the manufacturing sector in the euro area every month and uses five balances of opinion from industry survey: production trends, order books, export order books, stocks and production expectations.
Please find the chart enclosed or combined with additional information at www.caef.eu.
Background information on CAEF:
CAEF is the umbrella organisation of the national European foundry associations. The organisation, founded in 1953, has 22 European member states and works to promote the economical, technical, legal and social interests of the European foundry industry. At the same time, CAEF implements activities which aim at developing national foundry industries and co- ordinating their shared international interests. The General Secretariat is situated in Düsseldorf since 1997.
CAEF represents 4 400 European foundries. Nearly 260 000 employees are generating a turnover of 39 billion Euro. European foundries are recruiting 20 000 workers and engineers per year. The main customer industries are e.g. the automotive, the general engineering and the building industries as well as the electrical engineering industry. No industrial sector exists without using casted components.
Further information at www.caef.eu and CAEF LinkedIn.
In addition, the GIFA FORUM will be held in Hall 13, D07. Below is an overview of the particular presentations.
Monday 12.06.2023 – 13:00 h
New opportunities for the optimisation of total process costs through innovative feeding technologies, by Marcus Friederici
Monday 12.06.2023 - 3 - 16:00 h
Analytical Study of the Components of Polyurethane Cold Box Binder Systems towards emissions, by Dr. Sritama Kar
Tuesday 13.06.2023 - 10:30 h
Improved Process and Quality Control through the use of 3D printed filters, by Ulrich Voigt
Furthermore, there is a daily VR Live presentation by ASK Chemicals, Hall 12, Stand A22. The subject is Cored Wire & Cut Inoculants in the virtual foundry and will be presented daily from 11:30 to 16:00h.
The concept of thermal stability has been incorporated in the 6th generation INOTEC promoters through the proven tooling concept. Thermal stability describes the resistance of the binder system to mechanical and thermal influences of casting applications. In this context, the INOTEC WJ 6500 promoter exhibits exceptionally high thermal stability, which counteracts deformation especially of filigree and thermally stressed core geometries, such as water jacket cores, during casting applications. In contrast, the INOTEC TC 6500 promoter has low thermal stability and is suitable for the production of voluminous core geometries. The complementary product formulations can be mixed in any ratio, so that a specific thermal stability can be set depending on the sand core geometry. The effect of different mixing ratios of the INOTEC promoters TC 6500 and WJ 6500 on the thermal stability of the binder system can be observed, for example, with a heating microscope (Figure 3). The change in area of a cubic test specimen consisting of INOTEC binder and INOTEC promoter is recorded with increasing temperature. A change in area of 5% is defined as the so-called softening temperature, so that conclusions can be drawn about the incipient softening of the binder system from the curve progression. The successive increase in the application rate of the thermostable INOTEC promoter WJ 6500 leads to an increase in thermal stability, recognizable by the increasing softening temperature.
In addition to these sand core-specific properties, a reduced addition rate for 6th generation promoters and thus increased material efficiency should also be highlighted. When using the product formulation alone, additionrates are reduced here by 31% (TC 6500) and 24% (WJ 6500) compared to 4th generation promoters.
In summary, the 6th generation INOTEC promoter system offers optimized moisture stability and can still be flexibly adapted to different customer requirements dueto the proven tooling concept of complimentary formulations. With the latest promoter generation, process stability for core storage, casting application and raw part processing is maximized..
"The man of the match" in the digitisation process is Jean-Pierre Hacquin, EDP manager at the Kempten iron foundry. He is one of few who always sees things from two perspectives: as a foundry man and an IT specialist. "There was always a follow-up project to use and develop the experience of previous projects, but also to balance out weaknesses of the last project," explains Hacquin. It turned out that at the beginning of the digitisation phase in the Kempten iron foundry, generally too little data had been collected. One of Hacquin's permanent projects is data processing.
"We had to retool machines, set up new IT structures and motivate employees. It was a long road, with many unforeseen problems that had to be managed. Everyone had to pull together," says Hacquin, who developed an app with the IPI and his team in the past, with information on the respective casting for the employees. However, the first version of the app was used less than expected. But Hacquin remains positive: "We continue to develop consistently, we keep entering new test phases, we keep trying out new things to see what works and what not. And it's always about taking the right people on board for a project."
Win-win situation for university and iron foundry
The cooperation with the university brings numerous advantages, as EDP manager Hacquin states. "Professor Hartmann supports us with the right people, so we get positive results." And from the Kempten University of Applied Sciences, too, the cooperation is seen as a win-win situation. "We need to have the right partners from the beginning to start a project and to make sure it keeps going. And with the Kempten iron foundry, that is the case," also emphasises Prof. Dr.-Ing. Frieder Heieck from the IPI.
Foundry manager Michael Windl also approves of the numerous advantages resulting from the cooperation, such as a cost saving of 5.4 per cent with the same production input: "I confirm: It's always a cooperation. You try to do everything together as a team." Yet, the secret of success of a successful cooperation lies not only in the togetherness, but also depends on the external framework conditions. "What it needs is a common frame in which one can operate well. It is crucial that financial scope and time are given and that partial successes are celebrated," says Windl.
What does digitalisation and AI mean regarding the foundry?
Artificial intelligence and digitalisation are related. The question is: what does digitalisation mean for the foundry? "What we want is to create an information base to facilitate work in the company, to become more efficient and effective, and ultimately to contribute to securing the future of the company. First of all, this is not about AI at all. Of course, we have AI projects when it comes to analysing and optimising complex process relationships. But first of all, the basis is data. In a foundry, an incredible number of processes run simultaneously, are extremely interconnected and often influence each other. And a sufficient data basis enables knowledge creation and forms the foundation for AI-supported operational decisions," explains Hartmann. This opinion is also shared by Managing Director Mr Hübner, who emphasises the economic efficiency of a project in this context. " Data collection has to pay off. Otherwise we don't get on the winning road and there are many trouble spots."
According to Hacquin, a consistent data structure now exists in the Kempten iron foundry. "A lot of data has been collected in the past. This is currently stored in a cloud, where many gigabytes of company data are already available for viewing and evaluation. This data forms the basis for the plant management and the management to make decisions," says the EDP manager.
The question is, how do we use the data?
Hacquin even goes one step further in his question: "The plants we have collect data anyway. Today, however, we are at the point where we want systems that collect data - individually for us. The basic question is: at what point in time can we collect information at all? For example, when a melting furnace is switched on, or when the crucible is changed?" Many projects fail not at the point of collecting data, but at the fundamental question of how the data can be used. The art, then, is to combine the findings of science with the experience of production. All of this is based on a common structured approach in order to work out objectives, wishes and necessities via the questioning technique. For Hacquin, the solution is to provide each department with the appropriate data. Or as Heieck sums it up: "Our goal is data networking at a high level in order to analyse meaningful correlations."
The "right" interpretation of the data by qualified personnel
Hartmann also states: "When it comes to finding the correlations - when it comes to comparing data - it is important that this is done by an IT specialist. That sounds easy to implement, but it is not so easy to find such people." The Kempten iron foundry is currently looking for the right personnel to analyse this immense variety of data "properly". Because according to Hacquin, in order to optimise a foundry, the selection process needs to be different from the one used for quality assurance or production planning, for example.
What are the advantages of digitalisation and the application of AI in the Kempten iron foundry?
The advantage is that high costs can be saved in the foundry. This applies, for example, to the question of when the most favourable time is to replace the crucibles. If they are replaced too early, this causes a large cost block in the new acquisition. If they are replaced too late, however, there is a risk of them cracking and melt escaping. AI can therefore be used to predict when the crucibles need to be replaced, taking into account the diverse and constantly changing process-related influencing variables. And today the Kempten foundry is at the point of being able to predict this precisely. According to Windl, these results provide completely new inputs. "Crucible wear has a big influence on energy consumption, but you don't even see that in the data without special analyses," says Windl. The task of AI is to recognise complex interdependencies in the data and make them usable for decisions about optimised process control.
With regard to the melting facility, Kempten's equipment supplier ABP Induction had solutions available for comprehensive data acquisition, but no specialised personnel to carry out company-specific data analyses. Florian Huber, research assistant at the Kempten University of Applied Sciences, has access to the entire data structure of the Kempten iron foundry, including all data from the energy management system. This makes the correlations between process management and energy consumption immediately visible and usable for appropriate optimisation measures.
Today, foundry plant manufacturers consciously advertise that their machines and plants provide a multitude of measurement data, whether melting plant or sand mixer. "But machines are first of all only data sources. The fact that they offer an AI that links data and offers solution suggestions does not exist in this way," says Hartmann. With the energy management system, energy consumption data is collected and statistically processed. But afterward, competences are needed that can precisely experiment with these data and intelligently link them with other production or process data. And this is exactly where AI process models come into play. The benefits and applicability of these models depend on the direct interaction of the competences involved, which in this case are the foundry itself, the furnace manufacturer ABP and the AI competence of the IPI. It is this cooperation of all the necessary experience and competences that forms the basis for the success of digitisation projects," says Hartmann.
How do you prepare employees for digitalisation?
Another issue concerns the insecurity of foundry employees when it comes to digitalisation. Because the mentality of foundry men is still more traditional. "All our casting reports are written by hand and then digitised in AV. There was an attempt to bring all casting reports into an app so that every employee could get information about what was produced the previous day, for example. But the project was stopped because the employees were not yet ready for this," says Kraus.
When it comes to digitalisation, however, a company depends on the support of its employees. But there is often a lack of transparency, which only reinforces employees' fears of "being replaced by the machine one day". Alexander Kraus, who is responsible for work preparation at the Kempten iron foundry, states. "Many of our employees - especially the older generation - cannot imagine what digitalisation means. They find it difficult to imagine that a machine should do the same as they do themselves. Yet it's not about replacing people with a machine at all, but supporting them in their work."
Changes in education and training in the foundry industry
A central issue for foundries is the adaptation of training and further education of their employees with regard to digitalisation. According to Heieck, this is precisely where engineering training should start. "Basic IT skills, e.g. in programming languages that are often used in web applications, in handling data and in machine learning (ML), should be an immediate part of engineering education. Engineers of tomorrow need to learn this," states Heieck. Finally, everyone in the discussion agrees that it is a matter of skilled personnel being able to see the big picture and to perceive the production process as a whole. This means that the interfaces between staff and process play a special role, which must be developed in the form of assistance systems that work and can be operated simply and effectively. "At the Institute, we are currently discussing how we can tackle this. We have to develop support tools for the workplaces in a digitalised production environment that are adapted to the respective employee task," states Hartmann.
Where does the journey lead? Future outlook of the Kempten iron foundry
The cooperation between the Kempten iron foundry and university will continue in the future, as all participants are highly motivated. "We want to take our future into our own hands and want to be in the premier league. We want to be better than our competitors by continuing project work, especially with the Kempten University of Applied Sciences," emphasises Roland Hübner, CEO of the Kempten iron foundry. Further primary goals are increased efficiency, stability and energy savings. The Kempten Iron Foundry also wants to create structures and a basic understanding of digitalisation and AI - step by step with time, patience and humility. In view of the serious shortage of skilled workers, the goal today is to secure the knowledge and experience within the company in such a way that it can be easily accessed by future generations of employees. Digitisation efforts at the Kempten iron foundry are always about to see the positive in joint projects and recording new successes. But the Kemptener's most important goal is to be one of the best foundries in Germany - on that point, everyone in the group agrees.
First of all, the engineers at Demisaş scrutinized their internal quality and foundry statistics. They noticed that one pattern seemed to be the most problematic, with an average scrap rate of 5.5%. The defect for this pattern had already been detected before both X-raying and machining the raw part. Now, the engineers decided to run a single simulation in order to identify the root cause of the defect on a virtual basis.
Manufacturing these sand cores using a 3D printing process makes it possible to optimize the cylinder head design, reducing consumption and significantly increasing engine efficiency. This technological improvement allows BMW Group Plant Landshut to stay at the forefront of its industry and repeatedly innovate, thanks to the flexibility of additive manufacturing.
The premium automaker needed a concept to automate and streamline the sand core additive manufacturing process. Until now, the pre-printing (raw material preparation and recycling) and post-printing operations (drying, removal and cleaning of the printed parts) were manual and tedious. So it was necessary to rethink the existing solutions and create a fully automated, integrated line.
Optimizing with MAGMASOFT ® autonomous engineering
To establish an optimized and robust process, a virtual Design of Experiments (DOE) using MAGMASOFT ® was performed. Within the DOE, 3 different feeder neck designs and different alloy chemistries for carbon and silicon were investigated. This helped the engineers to define the best process conditions for eliminating the porosity.To keep the task efficient, 64 different designs were investigated in the DOE, running solidification simulations only. The outcome showed that best chemical composition to reduces the problems, but it also pointed out that the feeder neck size had almost no effect on eliminating the porosity.
Yet, even with the optimized chemical compositionm, it became clear that despite some improvements the defect would still be present at an unsatisfactory high level. Therefore, Demisaş decided to run another DOE considering the feeder position as a variable.
The first DOE indicated the casting quality was not very sensitive to the feeder size. Therefore, the engineers concluded that the problem was mainly due to the feeding distance. Consequently, the feeder location was varied. As quality criteria, Fraction Liquid, Porosity and Hot Spot FS time were all selected to assess the outcome. Four designs were run with both filling and solidification.
After this successful case, Demisaş decided to apply the methodology of MAGMASOFT ® autonomus engineering for other problematic patterns and to review their development processes for new patterns to work more effectively.
Demisaş
About Demisaş
Demisaş, Turkey, was founded in 1974 and is now one of the leading companies in the European foundry industry for gray, ductile and CGI iron castings covering a wide spectrum of brake and security parts.
The BMW Group Plant Landshut, Loramendi and voxeljet development teams have tested and validated the equipment and processes to demonstrate the feasibility of an automated additive manufacturing line for large-scale production. Strong team cooperation coupled with the flexibility of the equipment developed under the ICP (Industrialization of Core Printing) brand have been key to the success of this cutting-edge Industry 4.0 project.
The ICP line is currently producing thousands of 3D printed cores per week to supply the mass production of the latest generation of BMW Group Plant Landshut’s engines. This technology combines 50 years’ experience in foundry with the advantages of additive manufacturing in a worldwide pioneering manufacturing line.
To learn more about this fascinating project and ICP technology, we encourage you to visit us at GIFA 2023, on the Loramendi & Aurrenak stand E26-E34 in hall 16. Our development team will provide you with insights into this game changing technology and will be glad to discuss the solution best suited to your specific core production needs. See you at GIFA! For interview requests, comments or suggestions relating to the Industrialization of Core Printing, please contact: info(at)loramendi.com
The list of well-known CONLED customers is long: in addition to the Lloyd shipyard, the Lürssen Group, Fassmer, Blohm + Voss, Frankenguss, and many more. Sachsenguss is currently retrofitting the entire site with CONLED and will generate savings of 28,020,693 kWh and 13,282 t of CO2 over the 10-year period in Chemnitz by retrofitting the entire site.
In the future, the ArcelorMittal plants in Bremen and Eisenhüttenstadt will be equipped with modern LED lighting throughout the entire site, thus achieving significant energy and CO 2 savings. In addition, optimum lighting will improve the quality of visual performance and thus enhance occupational safety and the well-being of employees. Both sites signed corresponding contracts with the company CONLED Lichtcontracting GmbH from Bremerhaven.
Especially for companies in continuous and three-shift operation with high energy costs, the refurbishment is an important and worthwhile investment that also has a positive impact on the environment. According to initial forecasts, the savings from the conversion of the entire plant in Bremen are likely to amount to around 9,000 metric tons of CO 2 and 18 million kWh of electricity per year, while values of 12,000 metric tons of CO 2 and 24 million kWh of electricity per year have been calculated for the Eisenhüttenstadt site.
"In terms of decarbonization and our sustainability strategy, we are pursuing several goals. Good lighting is also a set screw with which we ensure ergonomics in the workplace: we continue to adapt working conditions to people. In CONLED, we have found a partner with the experience and expertise to equip our plants with forward-looking lighting technology," says Reiner Blaschek, CEO of ArcelorMittal Germany.
"Operating a steel mill is predestined for conversion to LED lighting. The lighting is in operation virtually non-stop, and the power requirement with the previous lighting is correspondingly high. Based on our contracting agreements, the savings are higher than the monthly costs. Economically, this is a very sensible solution that is also environmentally friendly," says CONLED Managing Director Jandirk H. Ebel.
The conversion time for both plants is estimated at three to four years. The size of the two sites poses a particular challenge. In addition, the lighting installations are mainly carried out during regular operation. CONLED guarantees better lighting conditions after the installation and takes over the regular maintenance. The goal is to save as much energy as possible by replacing the luminaires and using sensor technology, while at the same time providing the best possible illumination of the production areas. CONLED relies on selected LED luminaires from renowned European luminaire manufacturers. The redesigned lighting is intended to provide a better and safer working atmosphere, especially during shift operations.
Walther Trowal at GIFA 2023
Düsseldorf/Germany, June 12 to 16, 2023
Hall 15 / Stand D15
JUTEC at GIFA/METEC/THERMPROCESS/NEWCAST 2023
Düsseldorf, Germany, June 12 – 16, 2023
Hall 10 / Stand H40
Visit us at the GIFA - GMTN in hall 13 stand no. A25
We look forward to seeing you with the whole team!
Visit also our hompage at: www.siempelkamp-giesserei.com
Stronger together
Kuhn Special Steel is part of Kuhn Industrie Holding. This corporate group brings together all the competence, experience and know-why of technology-leading organisations in the centrifugal casting sector.
As a leader in the centrifugal casting industry, Kuhn Special Steel does not just track current developments; it drives them forward at its own initiative. Ever since the company was founded, it has been developing and designing centrifugal casting machines tailored to its specific needs. Since 2020, Kuhn Special Steel has been even more strongly positioned in this area. The company kuhn.innovation, also a member of the Kuhn Industrie Holding, supports the automation and digitalization of the group's foundries with 8 experts in the fields of mechanical and electrical design and also optimizes production in terms of machine safety and energy efficiency.
ISO DIN-Certifications etc.
We are certified in accordance with:
- ISO 9001
- ISO 50001
- AD 2000 WO
- PED 2014-68-EU
- ISO 3834
- Lloyd´s Register
- DNV
- ABS
- DIN 2303
DigJim from Norway - ultra-fast maintenance system.
This user-initiated innovation is a patented system for the rapid replacement of parts to protect buckets on construction sites. This solution enables new flexible and sustainable ways of working during maintenance. In addition, a modified design of the teeth in the DigJim system makes better use of the wear resistance of the steel. This has led to a demonstrable increase in productivity in the field.
For a new, ultra-fast maintenance system with lower operating costs and higher productivity, DigJim has been nominated for the Swedish Steel Prize 2023.
Gestamp from Spain - front lower control arm
In a very demanding application, Gestamp puts the material properties to the test in terms of strength and formability. This central part of the chassis is crucial for both daily operation and vehicle safety. Using the latest forming technology, the front lower control arm has been given an optimized single-shell design, made possible by the introduction of a new material strength level.
Gestamp has been nominated for the Swedish Steel Prize 2023 for an optimized front lower control arm with better behavior, lower weight and lower cost.
Green Buffers from Sweden - new generation train coupling technology.
Green Buffers introduces high-strength steel for energy absorption between railcars to increase train safety. This new generation in coupler technology enables more complex customized solutions and offers an expanded number of well-defined, robust performance levels for energy absorption. Since existing railcars can be retrofitted, the technology can be introduced quickly and rail safety improved rapidly.
Green Buffers has been nominated for the Swedish Steel Prize 2023 for the new system, which supports the company's vision of zero uncontrolled derailments in collisions.
Levistor from the UK and ZOOZ from Israel - mechanical battery for fast charging.
These high-performance mechanical batteries with a new steel flywheel design are sustainable solutions for a more sustainable world. Mechanical batteries have a longer life, no energy loss and a smaller environmental footprint compared to chemical batteries. This modernized steel solution also achieves safer operation by replacing conventional flywheel designs with layers of high-strength steel, preventing insulation failures and limiting associated damage.
Levistor and ZOOZ have been nominated for the Swedish Steel Prize 2023 for the development of a new steel flywheel design that offers increased safety, extended service life and lower life cycle costs with a 100% recyclable material.
Most prestigious steel prize in the world
The Swedish Steel Prize recognizes outstanding design, collaboration and innovation in the steel industry that contributes to a better and more sustainable world. It aims to inspire engineers, designers and inventors to further develop the unlimited potential of steel.
Source: www.ins-news.com
Take the chance and join the 1st Foundry Young Researchers and Early Career Professionals Conference which takes place on 18th April 2023 on a digital online platform. The conference will be offered three times during this day and provides advanced technical knowledge in Casting Solutions, Digital Foundry, Circular Economy and Sustainability, presented by Young researchers and Professionals. Register here!
New products for the melt shop
ROTOCLENE is a new process for producing the highest quality, inclusion-free steel for casting. We will display the whole process at our stand, with an hourly presentation to introduce the theory, practice, and benefits.
The process uses rotary action to stir the metal and disperse fine argon bubbles through the melt. These bubbles are highly effective at catching any inclusions and bi-films, floating them to the melt surface, where they are trapped in the slag layer. The rotary action also homogenises melt temperature and eliminates cold spots. This allows the steel to be poured at lower temperatures, reducing shrinkage and promoting finer microstructures. This is all possible in a standard bottom pour ladle.
Having cleaned the steel, it is important to avoid further inclusions developing in the melt during pouring – the job of our HOLLOTEX shroud filtration system. Combining the benefits of STELEX filters with shrouding technology, the HOLLOTEX shroud allows pouring of large castings quickly and effectively, without the turbulence that creates these oxide inclusions. The latest incarnations of the HOLLOTEX system will be on show at GIFA 2023, including demonstration of an improved and simplified method of achieving an air-tight seal.
Finally, we will display new temperature sensing and analysis equipment from Vesuvius’ Sensors and Probes division. The FERROLAB V thermal analysis system provides real-time measurement of %Ceq, %C, %Si, and the nucleation status of the iron. This provides the operator with the insight needed to take immediate corrective action, within predetermined process specification, to protect the quality of the iron. Benefits include reduced scrap rate, as well as improvements in the quality and consistency of castings.
Flow control
At GIFA 2023, we will highlight the latest flow control technologies for steel ladles and auto-pour iron applications, which save time on maintenance and repair, as well as extending life.
The VAPEX FosFlow is an alternative nozzle system for bottom pour ladles for steel and runners/tundishes for casting iron. The system allows nozzle change from the bottom, without any refractory maintenance. Nozzle change is thus achieved more quickly and safely – important when time is key or a different inner diameter of the nozzle is needed.
We will also introduce two new mixes of our VISO stopper technology, which extend stopper life and/or eliminate the need for preheating. VISO stoppers are the ideal choice when using a KALTEK ladle lining, allowing foundries to reduce their environmental footprint and cut CO2 emissions.
Furnace refractory linings
A complete lining package, designed for long life and improved metal cleanliness in coreless induction furnaces melting steel grades, will be on display at GIFA 2023. The portfolio consists of high-quality KELLUNDITE lining systems, suitable for melting a wide range of steels, in combination with an optimised sintered profile that allows enough powder at the back to run the furnace safely.
In addition, we will show a complete package of long-life linings for long campaign cupolas melting iron grades. The cupola portfolio consists of high-quality RAMWELL ramming mixes and HYDRA-MAX low cement castable lining systems, enriched with silicon carbide and graphite aggregates, to improve slag resistance.
Innovative sand core binder solution for HPDC
A key limitation of the high pressure die casting process (HPDC) is the inability to produce complex, hollow castings, at high volume, and in a cost-effective and sustainable way. This is due to the difficulty in producing suitable cores. Standard sand cores cannot be used, as they are difficult to remove after casting and do not provide adequate surface finish. Salt cores are more suitable, but are expensive to produce and present other operational limitations.
In response to this challenge, we have developed the WASCO water-soluble binder and coating, which we will showcase at GIFA 2023. This innovative binder system demonstrates high bending strength and has been used successfully in both liquid and semi-solid HPDC processes, even in severe conditions. With the use of an appropriate coating, WASCO-based sand cores can exceed 1000N/cm² and are thermally resistant up to 750°C. Post-casting removal is achieved simply by flushing with water, preventing any risk of damage or crack initiation.
Methoding and coatings for aluminium foundries
The methoding area at GIFA 2023 will highlight the optimal use of foam filters, die coating, and feeding systems in sand and gravity die casting applications.
Applications will be shown for aluminium and copper base castings, demonstrating excellent yield combined with improved casting quality. We will also highlight the FEEDEX NF1 range of exothermic feeders designed for both aluminium and copper applications. This sleeve material is highly exothermic, provides quick ignition, and has high strength. Due to its excellent feeding performance, manual application of exothermic powders is also avoided, reducing emissions.
The new range of DYCOTE SAFEGUARD products will also be highlighted. These long lasting, nano-ceramic coatings are designed to achieve significantly longer service life compared to traditional die coatings, leading to reduced interruptions for touch-up – and therefore increased productivity. This new die coating requires only a single spray, resulting in significant time savings and ease of operation. Multiple mixers and spray guns as in the past are no longer necessary.
Finally, new case studies that describe a filter and sleeve combination with conventional running and gating systems used in high quality, technically demanding applications will be displayed. All relevant exhibits will also feature simulations using the most recent version of the Foseco Pro Module for MAGMASOFT.
Visit us at the GIFA - GMTN in hall 10 stand no. F72
We look forward to seeing you with the whole team!
Visit us at the GIFA - in hall 16, booth no. E25!
We look forward to seeing you!
Visit also our homepage at: https://www.erdwich.com/en/
ERDWICH. Shredding unlimited.
Visit us at the GIFA - GMTN in hall 13 stand no. A25
We look forward to seeing you with the whole team!
Visit also our hompage at: www.siempelkamp-giesserei.com
Visit us at the GIFA - GMTN in hall 17 stand no. D41
We look forward to seeing you with the whole team!
Visit also our hompage at: www.generalkinematics.com
Visit us at the GIFA - GMTN in hall 17 stand no. D41
We look forward to seeing you with the whole team!
Visit also our hompage at: www.generalkinematics.com
Visit us at the GIFA - GMTN in hall 17 stand no. A38
We look forward to seeing you with the whole team!
Visit also our hompage at: www.savelli.it
Visit us at the GIFA - GMTN in hall 17 stand no. D61
We look forward to seeing you with the whole team!
Visit also our hompage at: www.reichmann.com
Visit us at the GIFA - GMTN in hall 11 stand no. B56
We look forward to seeing you with the whole team!
Visit also our hompage at: www.wollin.de
Visit us at the GIFA - GMTN in hall 11 stand no. B56
We look forward to seeing you with the whole team!
Visit also our hompage at: www.aed-automation.de
CITNM focuses on developing two structural parts of the electric scooter, produced in sand-cast aluminium alloy. Due to their relevance for the development, CITNM selected the scooter's rear swing arm and side beams (left and right).
The process - from development and optimization to production – is presented below. The castings of the prototype parts were carried out at Firmago – Fundição de Alumínios, S.A, in Portugal.
Rear swing arm
The rear swing arm was the highlight of component development. It connects the driving wheel to the frame and suspension of the scooter.
The primary goal in developing this part was to reduce the weight of the component, and thus the scooter's overall weight, without compromising its mechanical properties.
The first step was to optimize the traditional design of the rear swing arm using a generative design – Figure 2 – which served as a basis for the final swing arm design of the Mobinext scooter – Figure 3.
This modification, from the traditional to the optimized design, resulted in a weight reduction of 10% for the same casting alloy
- A356.0. Although this was already a good achievement, some additional changes were performed to the alloy to improve even further the weight reduction.
A comparison of the mechanical properties of different aluminium sand-casting alloys showed that a reduction in thickness was possible by changing from A356.0 to A357.0. Tables 1 and 2 show both alloy's chemical composition and mechanical properties.
Table 1 - Chemical composition of the aluminium alloys.
%QC | A356.0 | A357.0 |
Si | 6,5-7,5 | 6,5-7,5 |
Mg | 0,2-0,45 | 0,45-0,6 |
Fe | 0-0,6 | 0-0,15 |
Mn | 0-0,35 | 0-0,03 |
Zn | 0-0,35 | 0-0,05 |
Cu | 0-0,25 | 0-0,05 |
Ti | 0-0,25 | 0-0,2 |
Outros | 0-0,15 | 0-0,15 |
Source: Granta EduPack
Table 2 - Mechanical properties of the aluminium alloys.
Properties | A356.0-T6 | A357.0-T6 |
Tensile strength (MPa) | 205-226 | 345-380 |
Yield strength (MPa) | 146-162 | 281-311 |
Young’s modulus (GPa) | 71,5-74,5 | 70,6-73,4 |
Elongation (%) | 2,1-2,5 | 2-2,4 |
Fatigue strength at 107 cycles (MPa) |
53,1-64,9 |
55,8-68,2 |
Fracture toughness (MPa.m0,5) |
19-21 |
20,7-23,9 |
Source: Granta EduPack
Together with the design optimization and alloy changes, the final version of the swing arm achieved an overall weight reduction of 20% – Figure 4.
After redesigning the rear swing arm, the challenge was how to produce it. It was not possible to use conventional sand moulds due to the part’s geometry. Therefore, the swing arm was casted in a 3D-printed sand mould.
To print the mould, it was first necessary to develop the gating system with its peculiarities. The development and production of the 3D printed mould was performed though a partnership between CITNM and BAMM (Spain).
Due to technical reasons, the mould was printed in 5 separate parts that were assembled before casting – Figure 5. After pouring, the sand mould was destroyed to extract the casting – Figure 6.
Finally, the casting was heat treated (T6), machined and painted to be assembled on the electric scooter prototype. It was the first rear swing arm prototype produced as part of the Mobinext project. To achieve maximum optimization there are still some adjustments to be done both in the part and process.
Side beams
The aim of producing a metallic side beam for the electric scooter was to increase its strength and reduce the damage caused by possible impacts/falls – Figure 7.
The side beams – left and right – were sand casted in A357.0-T6 aluminium, the same alloy used for the rear swing arm. Although it’s not a method of innovative manufacture, considering the dimensions (940x600 mm) and design of this component, it is often replaced by injection moulding. By selecting this process, the aim was to build a robust part and optimize the process parameters to overcome the geometric limitations that are associated with it. The prototype side beams were successfully casted and integrated into the electric scooter – Figure 8.
Prototype presentation
The Mobinext project is in its last development year.
The electric scooter prototype was presented at EICMA (International Motorcycle and Accessories Exhibition) in Milan on the 8th of November 2022, – Figure 9. It stands out for its aluminium frame, weight reduction, powerful e-motor, and by the front tire that is wider than usual, which aids in driving, even on uneven floors. These features were widely applauded by EICMA visitors. Removable batteries are housed under the seat, allowing for easy swapping. The driver's helmet is also stored inside the seat and it is planned to incorporate a top case to stow the passenger's helmet.
The start of road test is scheduled for the beginning of 2023. The Mobinext project will end in June 2023 with a national presentation of the final prototype.
Learn more about Mobinext at: Home | Citnm
Despite the – in our opinion certainly appropriate – decision to postpone the Euroguss to June, one attraction happening in this context nevertheless took place:
The awarding of prizes for castings at the European Die Casting Awards. This European die casting competition organized by the Verband Deutscher Druckgießereien e.V. (VDD) aims to honor die cast products made of aluminum, magnesium and zinc that are particularly innovative and technically sophisticated.
In this context, we were pleased that again some of our Trennex customers received awards this year, and we would like to take this opportunity to congratulate Albert Handtmann Metallgusswerk GmbH & Co. KG in Biberach, Torun Bark Magnesium GmbH in Schömberg, and Teilemacherei GmbH in Heilbronn for their prizes.
The award-winning castings show that die casting is constantly finding new applications regarding the reduction of costly production steps and saving weight.
We are pleased that we have been able to make a small contribution with our products to the success of the respective efforts and that they have been recognized in this way. In the end, we hope that the situation will have eased by June, and want to express our pleasure with which we look forward to the Euroguss in – hopefully - usual manner. Certainly, after this long period of limited contacts, for sure there will be much to talk about and discuss.
An example of this is the increasing need for pressure die-cast aluminum components, which place the highest demands on the casting process and component quality and which are demolded from the mold tools with tailor-made Chem-Trend release agents. Afterwards, the modern, water-based high-performance cleaners from SurTec remove the release agents without leaving residues and prepare the components optimally for further processing, for example, with the newly developed chromium(VI)-free passivations from SurTec.
SurTec and Chem-Trend provide technologically coordinated and tailor-made solutions for the entire production and value-added process of the components. Their own, jointly undertaken, complex and in-depth studies, together with close collaboration with external research institutions, offers users unsurpassed, perfectly coordinated comprehensive concepts from a single source.
At EUROGUSS 2022, on 18 -20 January 2022, the specialists from SurTec and Chem-Trend will be available in Hall 7A, Stand 7A-110, to respond to all your questions on process optimization and to advise users on the specific challenges in the production process.
About SurTec
The surface-technology company SurTec develops, produces and markets specialty chemicals for surface treatments. Its four fields of application, industrial part cleaning, metal pre-treatment, functional and decorative electroplating, cover the sector’s complete portfolio. SurTec is certified in accordance with the international standard ISO 9001 (quality management). Its additional certifications in accordance with OHSAS 18001 and ISO 14001 underscore its important corporate objectives of occupational health and safety as well as environmental sustainability and resource conservation.
The SurTec Group, with headquarters in Bensheim, Germany, is part of Freudenberg Chemical Specialities SE & Co. KG, and it operates in 22 countries with its own companies and in more than 20 countries through partner companies.
About Chem-Trend
Chem-Trend is the most proven partner in the world for release agents, purging compounds, and other process chemical specialties. Using a customer-centric approach and deep research and development, Chem-Trend is dedicated to improving production efficiency, reducing waste, and minimizing the impact on the environment for its customers. Founded in 1960 and headquartered in Howell, Michigan, Chem-Trend offers a globally integrated network of experienced, knowledgeable, and insightful production and technical experts in all major manufacturing regions around the world, serving customers through offices in North America, South America, Asia, and Europe. Chem-Trend is part of Freudenberg Chemical Specialities SE & Co. KG, a global technology group. For more information, visit CHEMTREND.COM
About Freudenberg Chemical Specialities
Freudenberg Chemical Specialities develops, produces and markets specialty chemicals. In order to be close to your customers, its five brands: Klüber Lubrication, Chem-Trend, OKS, SurTec and Capol maintain a worldwide market presence. Freudenberg Chemical Specialities is one of the world’s leading providers of special lubricants, release agents and products for chemical surface technology, as well as chemotechnical products for servicing and maintenance and solutions for the refinement of confectionery products and other food products. The Group has its headquarters in Germany, with member companies in more than 40 countries, which employee more than 3,800 workers and have annual sales of roughly €1.1 billion.
From right: Prof. Dr.-Ing. Martin Fehlbier, Eric Bader (Managing Director ExOne), Necip Cirakman
| Family | Type | Name | Supporting AM Technologies |
| Aluminum | (Pure or unspecified alloy) | Kinetic, WAAM, binder jetting*** | |
| Aluminum Alloy | A205 | A20X | L-PBF |
| Aluminum Alloy | AlMgSc | Scalmalloy | L-PBF |
| Aluminum Alloy | AlSi10Mg | 4046 | L-PBF, L-DED, WAAM |
| Aluminum Alloy | AlSi7Mg | F357, 4018 | L-PBF, WAAM |
| Aluminum Alloy | Al-5% Si | 4043 | EBAM, WAM |
| Aluminum Alloy | Al-Zr-Fe | CP1 | L-PBF |
| Aluminum Alloy | Al-Mn-Ni-Cu-Zr | HT1 | L-PBF |
| Aluminum Alloys | AlMgSc | AA5028* | WAAM |
| Aluminum Alloy | Al, Cu | 2319 | EBAM, CMT-WAAM, PTA-WAAM |
| Aluminum Alloy | AlCu | RS-230 | L-PBF, WAAM*** |
| Aluminum Alloy | AlSiNi | RS-390 | L-PBF, WAAM*** |
| Aluminum Alloy | AlMg | RS-507 | L-PBF, WAAM*** |
| Aluminum Alloy | Al, Cu | 2024 | CMT-WAAM |
| Aluminum Alloy | Al, Si, Mg | 6061 | L-PBF, bound metal, Kinetic |
| Aluminum Alloy | AlMg4.5Mn0.7 | 5183 | WAM, WAAM |
| Aluminum Alloy | Al, Mg | 5356 | WAM, WAAM |
| Aluminum Alloy | AlMg4.5MnZr | 5087 | WAM, CPT-WAAM |
| Aluminum Alloy | Al 94.65%/Mg 5%/Mn 0.35% | 5056 | Kinetic |
| Aluminum Alloy | Al, Zi, Mg | 7075 | Kinetic |
Here is an overview of the EMEA repair center’s capabilities and expertise:
| System | Tasks |
| HandySCAN 300/307/700 | Repair & calibration |
| HandySCAN BLACK / BLACK Elite | Repair & calibration ISO 17025 |
| Go!SCAN 20/50 | Repair & calibration |
| Go!SCAN SPARK | Repair & calibration |
| C-Track 3rd GEN | Repair & calibration ISO 17025 |
| C-Track 4th GEN | Repair & calibration ISO 17025 |
| MetraSCAN 350/750 | Repair & calibration |
| MetraSCAN BLACK | Repair & calibration ISO 17025 |
“We have at heart to provide a quality of service at least as good as our systems!” claimed Fanny Truchon, President & Business Unit Manager at Creaform. “We trust these service improvements will prove instrumental in relieving our existing and future EMEA customers from delays and costs associated with the logistics of a point of service located on a whole other continent. This marks the end of a journey that started in February 2021—when we started looking for a suitable site— but also opens an era of simplicity and autonomy for us and our customers in the region,” she concluded.
The year 2022 also marked an important sustainability milestone for Bühler as the company announced the next stage with more concrete targets and action plans. Bühler developed a strategy to reduce greenhouse gas emissions in its operations by 60% by 2030 and also committed to providing solutions that reduce energy, waste, and water in its customers' value chains by 50% by 20251 .
To keep the pace of innovation high, research and development (R&D) spending remained stable at CHF 141 million or 4.7% of Group sales, in line with Bühler's strategy to be a technology leader in its selected industry segments. As part of its innovation promise to sustainably change value chains, Bühler launched some 40 new products in 2022, including six new core products.
Investing in people
Bühler was able to achieve these good results despite the many challenges in its markets thanks to the dedication and commitment of its employees. All our employees around the world have shown great commitment and perseverance. Our colleagues at Buhler China deserve a special mention. Although they faced strict zero-covid restrictions, regional lockdowns, and power outages, they kept production running.
In 2022, Bühler expanded and added to its development and lifelong learning programs for its more than 12,700 employees worldwide. In 2022, Bühler hired 230 new apprentices in Europe, North America, South America, Africa, and Asia, who are trained in three- and four-year courses in nine different professional fields. In total, Bühler employs over 500 apprentices worldwide.
Creation of a single Food segment and increased focus on services
To further increase the added value for customers, Buhler will integrate its Consumer Foods segment into the Grains & Food segment and focus more strongly on its service offering throughout the Group. A harmonized Food and Feed segment will enable more direct interfaces with customers, and processes will become more efficient as a result. Johannes Wick, CEO of Grains & Food, will head the segment. Germar Wacker, who previously headed the Consumer Foods segment, will take on new responsibilities outside Buhler. He will support Johannes Wick in the transition and will leave the company at the end of the first quarter of 2023. "We thank Germar Wacker for his great contribution to the successful acquisition of the Haas Group and wish him all the best for his personal and professional future," says CEO Stefan Scheiber.
In order to accelerate the positive development of Bühler's service business, Samuel Schär, who held the positions of CEO Advanced Materials and Chief Services & Sales Officer, will in the future focus entirely on heading the global Services & Sales organization. Marcel Natterer will now head the Advanced Materials business unit; he has successfully led Buhler's Value Nutrition business unit for the past ten years. He has also been appointed a member of the Bühler Executive Board.
Outlook: Continued positive development
While 2023 will most likely remain challenging, Bühler starts the year with a solid financial position and a high order backlog. Thanks to the developments in its markets, Bühler sees numerous business opportunities to offer solutions with added value and impact for its customers.
Despite all the uncertainties, Bühler intends to continue its positive development. "Overall, we are convinced that Bühler is well positioned to take another positive step in its successful business development in 2023, even in a very dynamic market environment," says CEO Stefan Scheiber.
Only very recently have AM-specific aluminum alloys begun to gain adoption in the market. The first and most popular one is Scalmalloy, which was developed and is currently marketed by aerospace specialists APWORKS (now part of Premium AEROTEC). Known service providers offering Scalmalloy manufacturing capabilities include some of the largest metal AM service providers in the world, such as 3T and Zare (acquired by BEAMIT), Sauber Engineering, Metron, https://www.3dprintingbusiness.directory/company/toolcraft/, PolyShape (now part of AddUp), Pankl and Quadrus Corporation.
Another popular aluminum alloy for AM is A20X, which was explicitly developed for additive manufacturing and can offer tensile strength up to 511 MPa, yield strength up to 440 MPa, and elongation at fracture up to 13%. A20X is now commercialized globally by ECKART, part of the ALTANA Group, after it acquired the original material developer AMT.
MX3D, the Dutch leader in WAAM technology, known for several high-profile applications, has also qualified a wide range of aluminum materials for its technology (available both via production services and the M1 hardware systemsì). These include AlSi10Mg (4046) and AlSi7Mg (4018) in wire form as well as 5356, and 5087. WAAM3D, a UK company that recently entered the market with the advanced and highly automated roboWAAM system, also offers aluminum wire, both 2319 and AlMgSc (with scandium, like aerospace-grade AA5028 but with a higher scandium content). The company supplies them in spools as large as 150 Kg, for extra-long production runs for both CMT-WAAM (cold metal transfer) and PTA-WAAM (plasma transferred arc) processes. WAAM3D also lists 2024 and 5087 alloys as available for both CMT and PTA WAAM processes but reports low demand for them.
Before the Russian invasion of Ukraine, RUSAL, one of the world’s largest aluminum manufacturers, launched the ALLOW series of aluminum products for AM which include both casting alloys and several alloys developed specifically for AM processes and optimized for sustainability and low energy demands. Among these are RS-230 AlCu (a hot crack–resistant 2xxx series alloy) and RS-390 AlSiNi alloys, which are suitable for applications up to 250 °C; and RS 507 AlMg and RS-553 AlMgSc alloys, which are corrosion-resistant, high-strength materials marketed at a significantly lower price than Scalmalloy. While the threatened full ban on Russian aluminum has not gone into effect, it is not clear at this time what the business perspectives for RUSAL aluminum powders are, even as the company produces as much as 6% of the world’s aluminum.
In 2020, French company Constellium launched Aheadd, a new generation of optimized high-performance aluminum powders for L-PBF. Among these, Aheadd CP1 (Al-Zr-Fe) is the preferred solution when high conductivity and increased productivity are required. Aheadd HT1 (Al-Mn-Ni-Cu-Zr) is a solution for high temperature and strength requirements.
Along with A20X, ALLOW and Aheadd, Canadian power manufacturer Equispheres launched Performance, Precision and Production aluminum powders for AM (which are both the brand names for each product and their intended uses). The company developed perfectly uniform, perfectly spherical powder improving process reliability, speed of production and part performance in AM, targeting opportunities for high-volume, lightweight AM parts. Equispheres has also partnered with TRUMPF, Lockheed Martin, Aconity3D and Morf3D to accelerate development.
Aluminum binder jetting
Equispheres aluminum powder is sinterable without modifications or additives. This provides a performance advantage on binder jetting printer platforms. With the binder jetting process lauded as the breakthrough needed to bring additive manufacturing to the next level, these inherently sinterable aluminum powders will open the doors for mass production of lightweight parts.
This brings us to the interesting topic of aluminum binder jetting. As metal PBF processes become more and more productive through larger, faster and more automated systems, the adoption and demand for aluminum alloys are expected to grow significantly. However, a major challenge to the widespread adoption of aluminum in AM is that the processes targeting large batch and serial production via AM, which would benefit the most from aluminum’s lower cost, are high-throughput binder jetting processes. In terms of materials development, these processes generally benefit from the ability to rapidly adapt metal materials initially envisioned for and used in MIM processes. Aluminum and its alloys are not among these
In binder jetting as in conventional MIM, the metal powder is first mixed with a binder in order to make it moldable or to build the part additively. The green part is then sintered in a furnace. The binder is removed and the oxide layer is reduced with heat. The metal powders join to form a solid object. Aluminum is challenging to sinter as the oxide layer surrounding the particles can only be removed at extremely high temperatures, while aluminum has a relatively low melting point, which restricts the maximum sintering temperature. It is therefore very challenging to remove the oxide layer on the aluminum powder before the entire metal piece has melted.
Solutions to this issue have been explored for several years, but full commercialization of aluminum as binder jettable materials has remained beyond reach. Today, however, this may be changing. In early 2021, both binder jetting companies Desktop Metal and ExOne (now merged) separately achieved major breakthroughs in the sintering of aluminum 6061 for parts produced by binder jetting technology.
The new powder from Desktop Metal enabled the sintering of unadulterated 6061 aluminum and represents a significant improvement over prior techniques used to sinter aluminum, which required coating powder particles, mixing sintering aids into powder, using binders containing expensive nanoparticles or adding metals such as lead, tin and magnesium. Critically, Desktop Metal’s powder also enabled compatibility with water-based binders and has a higher minimum ignition energy (MIE) relative to other commercially available 6061 aluminum powders, resulting in an improved safety profile. Desktop Metal and Uniformity Labs are working to qualify the powder and scale production for commercial release. Once fully qualified, Uniformity 6061 aluminum will be available for use with the Desktop Metal Production System platform.
The potential of aluminum as a material for binder jetting is significant and Ricoh has so far centered its entire metal AM strategy on this specific segment. Although its technology is not yet marketed, it has already proven the ability to produce complex and fairly large parts.
Aluminum for kinetic consolidation
Another Australian company, SPEE3D, supports high-speed, large-format 3D printing of (non-spherical) aluminum powders (including 6061, 5056, and 7075) via its Supersonic 3D Deposition technology, a type of kinetic consolidation (aka cold blown powder). This is the name given to the patented process in which a rocket nozzle accelerates air up to three times the speed of sound, into which metal powder is injected and then deposited onto a substrate maneuvered by a six-axis robotic arm. In this process the sheer kinetic energy of the particles hitting each other causes the powders to bind together to form a high-density part with metallurgical properties superior to casting.
Wire-based aluminum 3D printing
Aluminum alloys could also prove to be valuable and very cost-effective materials for high-throughput WAAM (wire arc additive manufacturing) processes. In fact, today, the majority of aluminum alloys are printable only via wire-based technologies. The use of various aluminum alloys across various types of WAAM technologies is also an actively researched field. Recent work shows that the most promising alloys are AlLi, AlCu, Al–Mg, AlZnMgCu, AlCuMg, AlSiMg, AlMgSi and AlMgMn/AlMg5Mn (these are of particular interest due to their high strength and corrosion resistance). Several wire-based metal DED companies around the world target aluminum as a key material.
AML3D, an Australian company marketing WAM (Wire Additive Manufacturing) technology through the Arcemy systems, supports the use of several aluminum alloys in wire form, specifically 2319, 4043, 5183, 5183 (0.2%Sc), 5356, and 5087. The WAM process is characterized under the 3D printing standards for Direct Energy Deposition, Compared to other wire-feed-stock metal printing techniques such as Electron Beam, Wire Fed Laser and Laser sintering processes, WAM can be used to print metal parts in an open free-form fabrication environment using a localized inert gas, reducing fabrication costs while improving material properties.
While aluminum support is often part of WAAM companies’ material strategies, it is also interesting to note that Meltio, a rapidly growing company marketing high-speed, low-cost, mainly metal wire-based AM systems, does not currently offer aluminum among its supported materials. It is also worth noting that Xerox recently abandoned its ElemX project, which was based on a liquid metal printing approach and saw aluminum as the primary material for the technology’s application and growth strategy.
In the US, MELD, a growing startup with a key interest in defense applications, developed a solid-state process (meaning the material does not reach the melting temperature during the process) to produce high-quality materials and parts with low residual stresses and full density with significantly lower energy requirements than more conventional fusion-based processes. The MELD process is capable of printing large metal parts at a scale not yet seen in the metal additive market and deposits material at least 10 times faster than fusion-based metal additive processes. MELD’s first commercially available machine, B8, uses solid bars of metal however different powders can also be combined to make a Metal Matrix Composite (MMC) such as Al-SiC, Al-Fe, Al-W, Al-Mo.
Among material suppliers, the AM materials portfolio of voestalpine Böhler includes a non-specified aluminum wire for WAAM. However, the use of WAAM with aluminum materials is still often limited by defects such as porosity and solidification cracks, which can severely limit the mechanical properties of the components, such as component strength or ductility. Recently a startup called Fortium Metals, which builds on the experience of Elementum 3D, entered the market focusing specifically on metal wire materials for additive manufacturing. Among its capabilities, the company offers “ideal metallurgy for welding the unweldable”, including 1xxx, 2xxx, 6xxx, and 7xxx series aluminum, by solving hot tearing and hot cracking issues.
Aluminum applications in AM
As metal developers and manufacturers introduce more AM-specific aluminum and aluminum alloy materials, the applications for the metal continue to grow. Today, though application potential remains largely untapped, there are some areas where aluminum AM is progressing.
Scalmalloy was developed specifically for aerospace applications and has the properties to back it up. The aluminum-magnesium-scandium powder alloy has a high strength-to-weight ratio, good ductility and corrosion resistance. Used in combination with topology optimization, the material can deliver lightweight, high-performance aircraft components. It is also worth mentioning that the aluminum alloy was used by APWORKS in the creation of the Light Rider, a 3D printed motorcycle back in 2016.
In the automotive and motorsport worlds, aluminum alloys are being implemented with 3D printing technologies. A notable case is the window guide rail on the BMW i8 Roadster. Made of aluminum alloy, the metal component weighs less than the injection-molded plastic part that is normally used but is still considerably stiffer. Its importance has already been recognized with an Altair Enlighten Award. Another key application saw Mercedes Benz 3D print one of the very first spare parts for the Trucks division back in 2017. Another key initiative, also dating back to 2017, saw Daimler, EOS and Premium Aerotec partners on the NextGen AM project whose main objective was to advance the automation of.the industrial 3D printing process, with a specific focus on the qualification of aluminum for use in industrial 3D printing. The project was brought to an end in 2019 as the companies said they had gained significant insights.
Motorsports is another high-growth area for AM, and aluminum can play a role. In 2020, Formula 1 approved the use of two Elementum 3D aluminum powders (A6061-RAM1 and A2024-RAM2) for the 2021 racing season. Elementum 3D’s A6061-RAM2 alloy was also used by aerospace startup Masten Space Systems to produce a 3D printed e-pump.
The luxury and hypercar automotive segment continues to be the most receptive to aluminum 3D printing, especially (at this time) for L-PBF applications. The most notable is the ongoing collaboration between Divergent and SLM Solutions on the Czinger21 supercar, which features as many as 350 3D printed parts on each vehicle, the majority of which are made using aluminum alloys.
Also notable in the automotive space is the German EDAG Group, which in 2020 developed an aluminum alloy for 3D printing automotive parts in cooperation with eight partners. The metal, CustAlloy, is engineered to be “crash-proof” and has higher strength and elongation at break than other aluminum AM materials. Looking at more widespread use in mass market automotive, Ford and binder jetting specialist ExOne (now part of Desktop Metal) developed a way to 3D print aluminum 6061 using binder jetting, as well as to sinter it. The process, capable of producing parts with 99% density, is still patent pending.
There is also a myriad of applications for aluminum alloys in the industrial sector, including the production of heat exchangers and heat sinks. Australian AM company Conflux Technology demonstrated how it could produce more efficient heat exchangers using AM and aluminum alloys. Specifically, the company showed a 3D printed heat exchanger built using the EOS M 290 3D printer and EOS’ AlSi10Mg material. The now-patented heat exchanger has various applications across a range of industries, including aerospace, automotive, oil & gas, chemical processing and microprocessor cooling.
Wire-based, large format applications (mainly via WAAM technology) have included the Aluminium Keel project, part of an ongoing collaboration between KM Yachtbuilders and MX3D to research and 3D print aluminum parts for the maritime industry. The aluminum 3D printed keel was produced using the company’s Robotic WAAM (Wire Arc Additive Manufacturing) process. Another recent project saw MX3D unveil a 3D printed aluminum bike, the Arc Bike II.
Speaking of large-format aluminum printed parts, the largest to date was produced by MELD Manufacturing. The US company used its unique friction consolidation 3D printing process to show off the scalability of its open-air capabilities by printing a ten-foot (3.05 meter) diameter aluminum cylinder, using off-the-shelf aluminum bars.
Quantifying the business of aluminum AM
By auditing every AM product on the market today, 3dpbm Research presented the most accurate overview of the metal AM market in terms of shipments recorded for each major material family. This provides the basis for material family–specific 10-year forecasts in the recently published Metal AM Market Trends and Opportunities report.
The report shows that the fastest-growing material families in AM are aluminum and copper. Aluminum is already widely used in powder AM processes, but until recently almost all aluminum AM powders on the market, including the most popular, AlSi10Mg, were casting alloys adapted for use in AM. Starting with Scalmalloy, introduced by APWORKS in 2016, and A20X, a new generation of aluminum alloys developed specifically for AM are now entering the market.
The main obstacle to aluminum adoption in AM is adapting the material for bound metal processes. BMP processes would be the largest consumers of aluminum alloys for AM, as the technologies target large volume cost-effective productions, were it not for the fact that they require the sintering of green parts in a furnace which remains a challenge that is only now starting to be addressed.
In terms of the metal AM materials demand forecast, the most evident change is the rapid increment in aluminum alloy adoption. Today aluminum alloys are the fourth most popular alloys after titanium and nickel, with 249.7 tons shipped in 2021, registering a growth of +36.7% compared to 2020. They will become the third most popular alloys by 2030, when they will represent nearly 20% of total metal AM material shipments, with 5,354 metric tonnes. The increase in aluminum demand could be even more significant if binder jetting technologies prove able to proficiently process it for serial production.
In terms of revenues, aluminum alloys represented the fourth largest material segment in 2020 with just $17.9 million (US) generated and growing by 36.8% in 2021. This gives us a better understanding of the size of the AM materials market. While growth will be significant, current revenues are very limited due to the small quantities needed to produce parts via 3D printing and the low numbers of parts generally produced via AM, whether for prototypes and tools (which are generally one-offs) or low batch production parts.
With that in mind, it is clear from the variety of potential applications and uses, that aluminum AM is destined to grow significantly over this decade. Among the currently established metal AM materials, aluminum alloys are expected to register the most significant CAGR at 33.3%, followed by titanium, steel, nickel and cobalt alloys. This will make aluminum and its alloys the third most relevant revenue opportunity at the end of the forecast period, generating $321 million in yearly sales by 2030 (over 1700% growth).
Source: www.3dprintingmedia.network
*This text was in part extrapolated from 3dpbm Research’s Metal AM Market Trends and Opportunities 2020-2030 report. It was updated to reflect the latest products and trends that have emerged.
With the addition of this software platform available to its industrial customers, Meltio takes another step forward in its commitment to improving the ease of use of its wire laser metal 3D printing technology. With this new ecosystem, Meltio takes another step forward in its firm commitment to offer a 360° solution to provide ease of use of its wire laser metal 3D printing technology in software and hardware. Meltio's end-user value is based on offering Freedom of choice and Healthy competition in a new market.
About Meltio:
Meltio takes metal additive manufacturing to the next level by developing high-performance, affordable, and easy-to-use metal 3D printing solutions using wire laser metal deposition technology. The company’s mission is to delight customers, partners and employees by pioneering the development of affordable metal 3D printing systems that are reliable, safe, and powerful, continually reinforcing their status as disruptors.
Die-Casting operations are – among other metal casting / foundry operations – on one side the last frontier when it comes to digital transformation and digitalization of company processes as ancient traditions carried forward by generations and huge amounts of experience may be replaced by modern state-of-the-art software-based company solution technologies, making the industry more attractive to young talent and providing new insights. On the other side die-casting companies are catching up when it comes to digitalization like no other industrial area. The reason for this is the relative process easiness in comparison to iron / steel casting operations.
Although metals & alloys have been melted and cast in foundries and for many centuries and for die-casting since many decades; ever since sophisticated planning and control systems were introduced, processes have changed, and these are now constantly being put to test.
Cost transparency, material and energy efficiency and process security in real time, combined with the much quoted “fast time to market”, have become essential if especially die-casting operations want to survive. The digital transformation in die-casting but very much in the foundry world is taking place right now with more and more interest in items like IoT = Internet of Things, BIG DATA management, Data Analytics and ultimately Data Visualization in real time – if possible.
In this paper, a case study of 2 totally different foundries are presented and on how a die-casting operation can achieve process controls using “Foundry 4.0” insights, but the journey to that goal can be long.
INTRODUCTION:
In a foundries business, like all competitive businesses, a good customer does not want a great deal nor the best deal. All he wants is a sustainable win-win FAIR deal. And a sustainable win-win FAIR deal is only possible when the supplier knows the right processes and have the expertise to manage the Product Actual Base Cost = ABC. You must know your ABC as it is YOUR strategic asset! This counts ESPECIALLY for metal casting operations!
By definition, ABC covers all the associated cost of raw metal materials, man-power direct cost, factory overhead, sales and the general administration cost all in a variable and fixed component where applicable. In metal casting we also name it C2C = Cost to Cast, comprising of more than just a BOM (Bill of Material) as it entails a “Bill of Operation”, “Bill of involved Machinery”, “Bill of Sequence of Work”, “Bill of Manpower used” and many more in a precise digital replication (digital twin = resource plan) of the metal casting process.
THE ACTUAL SITUATION:
In most foundries that we have worked with, unfortunately, many do not know their real ABC. This happens because, often times, one fails to recognize that knowing the foundries process and knowing the foundries business are two different things. These two are inter-related and NOT mutually exclusive. If they are treated incorrectly, one may end up either overprice itself out of the market or in the other extreme case, underprice too low to even stay in the business. Many foundries we worked with look for $/kg pricing on their castings. That merely reflects (sometimes poor) assumptions and does not reflect actual situations happening daily. The more is assumed the rougher the ABC becomes the less precision is prevailing.
Furthermore, in many foundries and due to the above-described situation, they assume they are profitable as at the end of the month the cashflow is positive. However, they forget that maybe only a fraction of castings produced / orders fulfilled really contributed to this, whereas other orders / other castings produced actually created a loss to the operations.
Implementation Barrier
Many foundries fail to recognize and provide the right infrastructure and resources to an effective implementation. Like all Digital Platforms, FRP® - Foundry Resource Planning Solutions - works on a Data Base that requires timely inputs in order to CAPTURE the Actual Cost Data; material quantity, labor factor, cycle time and tie that to the product identification. In many foundries that we worked with, digital platforms as such fail to take off because of inadequate resources for the data inputs and the culture to sustain the system.
The challenges of determining a product ABC = C2C in foundries business are as per below and is considering all aspects of the main casting process having a discontinuous workflow. If foundries put their operations on an integrated digital platform with a seamless reporting chain and fully understand the importance of deploying a digital twin model in their daily operations, then they can easily overcome the described challenges.
THE 3 – “ABC” & “C2C” - CHALLENGES:
#1. Metal Price Volatility:
Metal price volatility, although some degree of adjustment is allowed in some cases, but few in between. With proper database correlation foundries could easily create “raw material price scenario manager” hence be in a position to enhance their resilience against any price volatility. This is easily done when raw material prices are not merely captioned in an Excel file but in form of an integrated database with automatic and real time adaptions to international price indices as well external sources web-site source (e.g. Steel-Mint, Metalshub, etc.).
When this is done, a metal casting / foundry procurement officer / manager will be in a positive position to even “predict” future trends and counter react in an early fashion / manner since he knows the actual production cost / raw materials consumed and compares easily with the planned figures.
#2. Process Uncertainties:
Process uncertainties associated especially in die-casting where tool life and the diecast machine operating conditions that make them determining a Standard Cycle Time impossible. In sand-casting the material conditions, melt quality, core quality and many more aspects contribute to these uncertainties. The metal casting process is THE ONLY manufacturing process where a product is shaped from a liquid. Hence, it is at times extremely difficult and involving a lot of guess work and numbers by experience, to check on the actual process conditions and accordingly on the process variables. The more this can be standardized again via bringing all on an integrated data platforms the better it is. Planning the process and making the plan precise is one thing. Executing the plan is another.
#3. Labor Cost:
Direct labor cost build-up as secondary process work increases with tool life. E.g. in die-casting extensive deburring and reworks that kill your profit because many times it is not accounted for. In sand casting you would talk about additional fettling and cleaning cost OR in further secondary processes in additional heat-treatment and machining cost. Also, here the major principle counts: what you cannot measure you cannot control and the better you plan and better execute the plan the better you will be able to get your labor cost and many others under proper control. This may also involve organizational control at times.
THE SOLUTION FOR “ABC” & “C2C” - TRANSPARENCY:
Therefore, an Integrated and Continual Process Management (ICPM) tool, driven by high integrity live data is the way forward to minimize the above uncertainties; eliminating surprises that eat into the bottom line, and a scientific way to drive your CVP (Cost Volume Profit).
The live data enable you to drill your cost down to each stock keeping unit (SKU) level (effectively that’s your multiple BOM-cost, see above) in a timely manner and to bench mark against the ABC = C2C; the result is a clear Price Quote Variance (PQV).
Furthermore, with a real time dashboard looking at your inventory in every foundry stage would allow you to minimise SKU levels and provide transparency on never seen before transparency. With this, what we call also “SeW-inventory” (Sequence of Work) you will be able to look at every order, at every foundry stage, at every product and at every single piece that is part of your current “rolling” inventory in your operations. Examples have shown that by just providing clear and tangible transparency in this area, real $$$-savings in a magnitude of US$ 80-100k in one year can be achieved for a typical SME – iron / steel or even die-casting foundry!
Again, production data MUST BE IN FORM OF A DIGITAL TWIN MODEL CAPTIONED PLATFORM, else it is not possible to achieve such number and many foundry / metal casting operations stay as a “black hole”.
FOUNDRY EXAMPLE AND CASE STUDY #1 FROM INDIA:
(pictures inside the presentation only)
This Aluminium die-casting foundry operates about 500 ton of castings every month. For IP-reasons the identity of this foundry is kept secret and not to divulge information that may compromise their competitive level.
The processes applied are purely LPDC / GDC and no HPDC in this location. From the various pictures seen in the presentation only there is no or very little data transparency and / or traceability of castings. The C2C is estimated and most if not all operational control is done using Excel files and paper and pencil, and only partially information is fed into the corporate system resulting in daily / weekly / monthly adjustment in terms of sequence of inventory and material management. Productivity is despite the volume and high labor-intensive production volume on a medium level with almost daily fire-fighting and production meetings. Still, they produce quality castings even for EV’s.
FOUNDRY EXAMPLE AND CASE STUDY #2 FROM INDIA:
(pictures inside the presentation only)
This Aluminium die-casting foundry operates a similar tonnage than example #1 however with much less manpower volume and higher amount in automation and digitalization deployment. Again, the identity of this foundry is kept secret and not to divulge information that may compromise their competitive level.
The process applied is LPDC only in this location with HPDC / GDC in other locations. From the various pictures seen in the presentation there is right from the beginning a very high level of data transparency and digital data collection available. Every casting is after its “birth” coded with a QR code and traced /tracked inside the factory. The process steps may differ for different casting models and as such the casting itself via the QR code can “tell it’s story” to the respective production sequence and site. This is btw, the true essence of what “Foundry 4.0” is all about. In addition to that, the furnaces are centrally monitored, energy consumption is digitally controlled, such as temperatures, metallurgical measurements and the like. In the end and at a pinnacle of production planning and controlling this foundry operates an MCT = Manufacturing Control Tower. All information comes to the “control room”, there are data analytics and other tools applied to make data driven decisions in real time and on-time. No lengthy meetings required and no manual interventions unless there is an un-planned and un-controlled occurrence. This foundry operates with the motto: What you cannot measure you cannot control and lives by this principle.
FRP® - FOUNDRY RESOURCE PLANNING SOLUTIONS:
FRP® - Foundry Resource Planning Solutions software is deploying a DIGITAL TWIN platform concept. This allows you to digitally replicate the complete manufacturing process of metal casting regardless of die-casting or sand-casting. The information used comprises more than a simple BOM since all labor, machinery, settings, materials and timings are considered and with this you will be able to do all production planning and very much controlling but also much more in a systemic Data Driven Continual Improvement that protects the Bottom Line in real-time. This is in its entirety completely different that classical corporate systems.
FRP® is an integral part of the ICPM tools mentioned above. You will know where you are going (with your monthly / quarterly / annual PnL in sight) before the month end closing and you have the precious lead time to manage your operating cost.
The end result is, you will always have the high integrity cost data at the SKU-level and that means your projections will be realistically accurate at all times.
With an accurate ABC = C2C at your disposal means you will have an ACCURATE and PRECISE quotation data and the right tool to manage your daily PnL. On the other hand, if you still use a Traditional Historic PnL Management, then this will render your effort "too late to correct the train" before it hits the wall.
Actual cost requires Actual Data and FRP is the digital tool available to compute the A-cost. Contrary to quoted cost that is based on Estimates Cost; E-Cost. Over time, the A-cost become the valuable cost data base that can be used as the BENCHMARK to more accurately form the basis for the next generation E-Cost.
SUMMARY
In today’s world (M)-SME foundries need intelligent solutions! It is not enough to merely rely on manpower especially in and labor-intensive processes. Cost optimizations start at the RFQ level especially for low volume / high mix operations but just as well in the reverse.
Big date is Big money, data analytics and data visualization in real time requires more than what classical enterprise software platforms deliver, especially when a typical MS-Excel economy develops under the Level 4 application. In such cases a MES system like the one introduced is paramount to be deployed.
Case studies from two totally different operations have been described but cannot be disclosed in paper form, only the neutralized pictures will be made available in the presentation itself but not the publication.
The competitiveness of metal casting enterprises depends very much on their ability to foster a digital mindset, only then they will start exploring and ultimately deploying modern state-of-the-art software-based systems allowing to reduce wastage and increase productivity.
Visit to DGS Druckguss Systeme AG
DGS Druckguss Systeme AG, based in St. Gallen, is a global developer and manufacturer of sophisticated die-cast components and system solutions made of aluminum and magnesium alloys. Prof. Dr. Lothar Kallien, head of the foundry laboratory at Aalen University, also gives lectures on foundry technology, among other things: "Establishing contacts with industry and possible employers for our students is important to us." The group received a warm welcome in St. Gallen and was given insights into production, finishing and quality control. Two former students from Aalen University, who now work at DGS, gave an overview of the parts that are manufactured at DGS. They were particularly proud of a new production line that runs almost autonomously. "During the company tour, it was impressive to see the sizes of the individual process steps of die casting," said one student. Not only the huge 4,400 ton die-casting machines, but also the mold used for casting to produce structural components for Audi, for example, or the melting furnaces in which the aluminum is heated until it liquefies.
Mechanical engineering students are in demand by industry
"Towards the end of the tour, we were advised to apply urgently to DGS after graduation, as they depend on students with experience and knowledge in foundry technology from Aalen University," one student reported.
Figure 2 shows the temperature distribution at the time the casting is ejected from the die. The distortion of a structural component during the casting process is composed of the “spring-back” during ejection of the part (stored elastic stresses are released when the component is removed from the die) and the subsequent (free) distortion caused by cooling to ambient temperature. Local areas with higher temperatures have a stronger effect than colder areas during cooling, ultimately causing the thermal distortion.
RD2005PAD - unique rotary nozzle for coating of planar materials
With the RD2005PAD, a rotary nozzle for coating with PlasmaPlus technology is now available for the first time. This process uses nanocoatings to create specifically functionalized surfaces that are tailor-made to meet customer requirements with regard to planar materials. The spectrum ranges from superhydrophobic, adhesion-promoting to superhydrophilic coatings. With the RD2005PAD, the first rotary nozzle with precursor feed, Plasmatreat is once again the pioneer. Until now, only static nozzles were used worldwide for this coating application, which had its focus in the selective modification of surfaces. The new nozzle, which rotates around a rotation axis, is now suitable for coating flat materials and now also offers the advantage of a particularly homogeneous treatment with high intensity in the PlasmaPlus process. This produces a reliable functional layer that enables optimum bonding, printing or painting of the coated surface.
We sourced 3D printing services before we invested in our own system, so we knew we could drive down time and costs, said Thomas Nielsen, CEO of Hanssons. The large-format size to build molds and cores and the fast production speeds attracted us to ExOne’s binder jetting solutions.
Thomas Nielsen
CEO Hanssons Foundry
PFW10LT Openair-Plasma nozzle - for temperature-sensitive material
With the new PFW10LT, Plasmatreat has developed a low-temperature nozzle that also activates thermally sensitive materials and surfaces with high intensity. It is designed for use at low temperatures below 60 °C and performs a particularly gentle pretreatment of plastics prior to subsequent processes, e.g. bonding. The plasma nozzle is particularly suitable for small treatment areas and contours such as boreholes or groove areas, for low-lying applications in 3D components or for medical components and products. The PFW10LT plasma nozzle is used for a treatment width of approx. 4 mm.
Hanssons installed an S-Max® Pro premium binder jetting system in 2020 and began providing precision tooling without the long wait and high cost of traditional patterns and core boxes.
Nielsen admits it takes time for customers to embrace the new technology but sees 3D printing growing as more companies see the benefits for rapid prototype castings. Hanssons also impresses clients with the high-quality and fine detail of the 3D printed cores that the team can deliver fast, even for single-piece production.
Being the first foundry in Denmark with an in-house sand 3D printer is a source of pride and a business opportunity. “Someone had to be the first,” Nielsen said. Hanssons 3D prints molds and cores not only for its casting customers, but also to supply other foundries with on-demand tooling for production. “We can offer local solutions to the market, and it helps reduce delivery times and ease supply chains even more when we can produce domestically for industrial buyers so they don’t have to order abroad.”
Figure 3 shows the measurement of the virtual distortion result without considering the pre-corrected distortion in MAGMASOFT ®. The maximum deviation from the nominal geometry is approx. +2.3 mm at the left end of the side connector. Measurements are performed using a so-called RPS positioning. The task of the reference point system (RPS) is the unambiguous positioning of the component in free space.
PFW100 Openair-Plasma nozzle - for flat surfaces
In order to treat flat components or surfaces at high process speeds and at the same time over a large width, the PFW100 is now available as a suitable plasma nozzle. It is particularly suitable for the pretreatment of heat-sensitive materials such as thin plastic films or textile products such as synthetic nonwovens. It can also be used for the surface cleaning of glass or metal. The PFW100 performs uniform pretreatment over a width of 100 mm per plasma nozzle at relative speeds of up to 200 m/min. The treatment width can be flexibly varied via the modular arrangement of several nozzles.
Fig. 4a shows the predicted distortion result from the simulation without pre-correction in the measurement software. The import of the simulated, distorted component into the virtual measurement tool used by VW enables the creation of a virtual measurement report, similar to the quality inspection of real components during series production. In this way, the calculated component distortion can be analyzed in any required detail and according to specification. Corresponding to the evaluation from the Measurement Perspective in MAGMASOFT ® (Fig. 3), here, too, the maximum deviation from the nominal geometry is at the left end of the side connector (RPS positioning).
Figure 4b depicts the distortion result from the simulation with the pre-corrected die geometry, also in the RPS positioning. It shows a significant reduction in casting distortion. Nearly all critical areas are within the specified tolerances for joining and functional surfaces of +/- 0.7 mm.
Figure 4c illustrates the real measurements of a cast sillboard side connector with the same parameters used for the distortion prediction with MAGMASOFT ®. The part is dimensionally completely within the specified tolerances and corresponds both qualitatively and quantitatively to the geometry predicted by the simulation.
The distortion predictions for the sillboard side connector from the casting process simulation with MAGMASOFT ® have shown good agreement with the measurement results on the actual cast part with pre-corrected geometry. The tooling modified based on the simulation resulted in most casting areas being in tolerance without the need for additional tool correction loops after the first trial. Before working with MAGMA, the precorrection in the die had to be determined by means of several casting trials.
The old method was expensive, cumbersome and sometimes led in the wrong direction. For VW, the new path is now no longer a one-way route: Large castings can be produced without long delays – and, above all, without distortion.
About Plasmatreat
Plasmatreat is an international leader in the development and manufacture of atmospheric plasma systems for the pretreatment of substrate surfaces. Whether plastic, metal, glass or paper - the industrial use of plasma technology modifies the properties of the surface in favor of the process requirements. Subsequent processes include bonding, painting, printing or gasketing.
Openair-Plasma® technology is used in automated and continuous manufacturing processes in almost every industrial sector. Examples include the automotive, electronics, transportation, packaging, consumer goods and textile industry, but the technology, cost and environmental advantages of the plasma technology are used in medical technology and in the renewable energy sector as well.
The Plasmatreat Group has technology centers in Germany, USA, Canada, China, and Japan. With its worldwide sales and service network, the company is represented in more than 30 countries by subsidiaries and sales partners.
For more information, please visit: www.plasmatreat.com
Visit to Bühler AG
Afterwards, the group went on to Bühler AG in Uzwil, where they were also warmly welcomed by Hermann Roos, the Structural Process Manager and also a former student of Aalen University. In the showroom, the students were shown the corporate divisions of Bühler. Two billion people eat food made with Buhler equipment every day, and one billion people ride in vehicles that contain die-cast components made with Buhler technologies. "Given this global relevance, our mechanical engineers who know foundry technology are immensely important for the challenges of the future," says Kallien. During the tour of development and production, the students were able to marvel at, among other things, the enormous casting unit of the new Carat with 8,400 tons of clamping force (the force that presses the mold halves together in die casting), which Buhler is currently setting up.
Further information on the courses of study
Students interested in Mechanical Engineering/Production and Management with the three elective specialisations Production, Business/Management and Digital Production
can find more information on the Instagram account maschinenbau.hsaalen, at www.maschinenbau-aalen.de or by WhatsApp to the mechanical engineering student advisory service on 0152 27 14 93 14.
Looking out of the window in the meeting room of Schmiedag’s administration onto the Volme, it is hard to believe what authorized signatory Detlev Müller recounts about the dramatic hours from July 14 to 15, 2021: “Due to the continuous rain, the Volme rose steadily and was already just below the bridge in the afternoon. Then I went over to the forge for a check, and when I came out of the hall again about half an hour later, the water was already flowing over the bridge decking.” Müller went back to the hall, had the production stopped immediately and evacuated all employees. 17 employees did not make it directly, Müller was one of them. The main escape route from the factory premises, the underpass to the B54, was flooded; the vehicles of the factory staff, which were still in the employee parking lot were lost. “When the water was about 30 centimeters on the site, I instructed everyone to climb onto one of the employee offices, where we could have used ladders to reach the roof of the hall in an emergency. Anything other than entrenching ourselves would have been too dangerous, because the water was coming from all sides and the current was unpredictable, with a tremendous flow speed.”
It was not only the water that proved problematic, but also the flotsam on the Volme, which was carried along by the masses of water and collected at and on the bridges on the plant site. The southernmost bridge with the most flotsam acted like a dam that could break at any time, so that even more water could have flowed uncontrollably toward the factory buildings in one fell swoop. “Meanwhile it was dark and if flotsam then breaks loose and is heading towards you, there is practically no escape. It was therefore clear to us that we had to spend the night on the factory premises, because any further attempt to escape would have been too dangerous. In the end, the water stood at a height of about 1.90 meters above the floor of the halls.”
This meant that all the facilities were also flooded. The team on the site had acted with foresight and de-energized the entire plant: “The electricians naturally think ahead in such situations, removed all the main switches and cut off the power supply, which subsequently turned out to be an advantage when it came to damage limitation and reconstruction”, Müller explains.
The team around Detlef Müller that remained on the premises was rescued by boats from the German armed forces early in the morning. Müller met later with a team to sound out the situation and check whether the site could be re-entered. “The water is one thing, but when it had receded, everything was full of mud – everywhere. And we had to deal with dust, for weeks, settling everywhere.” ABP’s warmer was also affected, was full of water, mud and residue.
The future of Schmiedag was hanging by a thread in this situation, as the technical manager of the Schmiedag GmbH, Heinz Klenen, explains: “If nothing works at all, neither electricity nor IT, and all machines are affected – then this was basically a total loss.” However, the company benefited from being part of the Georgsmarienhütte Group. “The colleagues were able to help quickly – we moved products to other locations, were able to use resources such as experts, or the group’s own company fire brigade, which was able to supply us with lots of material that we didn’t even have here – from shovels to wheelbarrows to pumps,” explains Detlef Müller, “the colleagues came at the weekend, pumped out and set up construction dryers.” The motivated team both in the group and at the Hagen site contributed a lot to the fact that Schmiedag was able to resume production comparatively quickly.
The colleagues from the group were also able to help with the power supply: For electrical switchgear and power feeds, a site from the group could help that had similar equipment as needed by Schmiedag. This allowed for much faster restart than if a completely new feed had been needed. With the help, high voltage could be brought to the site in late August 2021 and the first plant could go back into operation. “With all the misfortune, there was also a lot of luck”, explains Heinz Klenen, “with the available replacement machines, for example, with quick help from the other plants, and the fact that we were just in the repair phase and had shut down the furnaces. All tempering furnaces were out of operation – much more could have happened if they had been running in full operation at high temperatures. They cannot be shut down in half an hour, especially since there was no warning whatsoever that such a flood disaster could hit us, and not even at short notice that masses of water were moving towards us.”
ABP Induction, too, was able to contribute to the quick return to normality. The ABP heating system type EBS 460 WK installed at Schmiedag was affected by the flood. A large part of the heater had been under water and was damaged and dirty after the water receded. An ABP team inspected the plant in November 2021 and prepared a quotation for a comprehensive modernization of the heater. Practically, all the relevant components of the heater had to be replaced and renewed, starting with the feeder panel with circuit breaker and fuses to the four IGBT converters with mains chokes, coupling choke, control boards and fan including control panel. All current transformers, voltage transformers and insulation monitoring were also affected, as well as the drive cabinet with all frequency converters and the control panel.
“As the old hardware was no longer available, new, up-to-date Siemens hardware was used. The program was upgraded to TIA. As a result, the control technology of the heating system is now again on a par with that of a new system”, explains Dr. Marco Rische, Director System Business at ABP Induction. ABP was also able to respond to special requests for the reconfiguration of the plant. The withdrawal at the heater was to be changed from an inclined lift to a robot withdrawal in the course of modernization. For this purpose, a coupler module was used to provide communication and signal transmission to the robot. The engineering also had to be adapted. To this end, ABP supplied a second light barrier so that block adhesives can be detected more efficiently.
The heater was brought to the ABP plant in Dortmund and completely refurbished. It had been completely overhauled already by mid-March 2022 and could be delivered to Schmiedag again. “It was important to us to help quickly and without complications and to improve the system in all possible places during the modernization. Today, the heater is as efficient as a new system”, explains Dr. Marco Rische. Aspects such as variability and energy consumption also play a role. The heater is appropriately tuned to loading and unloading, the operation is optimized in terms of energy, and due to the introduction of the robot unloading, also for throughput.
The other systems and equipment at Schmiedag were also put back into operation step by step. The backup server with all relevant operational and customer data, for example, was well protected. “Fortunately, we had planned the server’s position so that it remained above the water surface.” This helped to resume operations: “Nothing would have worked without the data.”
Even long-time employees cannot remember such a similar disaster: A colleague in the maintenance department has been here for just under 45 years now and had never seen anything like this. You cannot deliberate on every scenario. But we are now differently prepared for possible cases in the future with the knowledge we have today.
About ABP Induction
ABP is a leading manufacturer of induction furnaces and systems for inductive melting and holding for the metal and metalworking industries. ABP is an expert in melting, pouring, holding and heating iron, steel and non-ferrous metals with design, production, assembly and services for foundries, forges and steelworks. The ABP Induction Group with over 400 employees has companies in the USA, Mexico, Sweden, Germany, South Africa, Russia, India, Thailand and China. It is represented by service and sales partners in most of the world's industrialized countries.
ABP’s portal “myABP.com” is the gateway into digitalisation. It provides foundry equipment documentation plus specialised hardware and software which support intelligent management of equipment and skills while enhancing communication between foundry personnel. It also offers virtual emotional learning environments and digital twins, as well as a fully automated service application that includes a ticketing application and a 24/7 spare parts web store.
“Foundries need to be able to bring their data together in one place and everyone will benefit from this practical, constructive agreement,” says Till Schreiter, President and CEO of ABP Induction Systems. “ABP and Norican are both highly motivated to help digitalise the foundry industry and linkages like this between different suppliers are vital to support completely connected digital eco-systems. Without them, it will be impossible for foundries to extract the full value from their data.”
For more information:
https://monitizerdigital.com
https://abpinduction.com/en/digitalsolutions/myabp-portal/
ae group shapes innovation for transmission and axle transmission casings, e-drive transmissions, engine components, battery housings, transmission control parts and structural parts. As aluminum is a key element for a more sustainable mobility and together their employees, ae group designs a successful and sustainable future for our environment.
Certification of ae group ag:
DIN EN ISO 9001 – Quality Management
DIN EN ISO 50001 – Energy Management
DIN EN ISO 14001 – Environmental Management
IATF 16949 – Automotive Quality Management
Figure 1: Fossil-fuel support by G-20 countries
Schematic representation of the current and new electricity price model:
Figure 1: Current electricity price model Figure 2: Proposed new electricity price model.
Effects of the new electricity price model
Advantages of an adapted electricity market design
- Significant and rapid relief effect for all electricity customers
- No fundamental change to the existing electricity market model necessary
- Positive impact on forward and OTC contracts
- No use of tax revenues necessary
- Effective location and future protection
1 The proposed import levy will contribute to a drastic and sustainable reduction in the purchase costs for electricity. This will make the purchase of energy more predictable again. Consumers will thus be directly relieved of energy costs and at the same time benefit from the inflation-busting effect. In contrast to the gas levy, which would have created additional burdens, this is a relief levy. 2.
2 The model continues to promote renewable energy suppliers, as the selling price to be achieved with this model will still be far above the production costs for wind, solar or biomass, thus maintaining the savings effect for electricity consumers.
Long detailed discussions on how to effectively skim off excess and windfall profits are avoided. Profits are maintained with the proposed model, but distorting excess profits are effectively limited. The energy wholesalers regulate the additional costs caused by imports themselves and do not pass them on to the consumers.
About Siempelkamp
Siempelkamp is a globally active group of companies with the business units Machine and Plant Engineering, Casting Technology as well as Engineering and Service. Approximately 3,000 employees worldwide ensure that the Siempelkamp Group is among the world leaders with its technologies.
The Siempelkamp Foundry in Krefeld specializes in the production of hand-formed large castings of up to 320 tons made of cast iron with nodular graphite. With a casting volume of 50,000 tons per year and 375 employees, it is one of the largest hand-forming foundries in the world. The comprehensive and customer-oriented service package includes the entire production process from design, calculations, pattern making, molding and casting to mechanical processing, packaging and transport.
About the BVMW association
The medium-sized business. BVMW e.V. is the largest politically independent and cross-sectoral interest association of small and medium-sized enterprises. Within the framework of the SME alliance, the umbrella organization BVMW also politically represents more than 30 associations of SMEs with a total of 900,000 members.
The share of G-20 fossil-fuel support allocated to coal is slowly shrinking – from 4.1% in 2016, to 2.9% in 2021. But coal still attracted a total of $20 billion of government support in 2021. This is surprising given that much of the effort to phase out fossil-fuel support has focused on coal, including pledges announced at recent G-20 summits and COP26.
While 2021 estimates are provisional, they suggest fossil support spending surged 16%. This spike was not simply due to economic recovery and higher energy use as 2021's total was 5% higher than 2016, a year in which energy use was approximately level. In fact, the 2021 increase was driven by a 16% increase in support to fossil-fuel producers and utilities.
“The G-20 and G-7 governments have announced a range of seemingly more ambitious commitments to phase out fossil-fuel subsidies,” said Victoria Cuming, head of global policy at BloombergNEF and lead author of the factbook. “But they always seem to include imprecise language and caveats, giving governments wiggle room to interpret these pledges as they wish. BNEF’s analysis shows that there seems to be little evidence of those countries delivering on their promises.”
At the national level, China may have accounted for the largest share (26%) of G-20 fossil-fuel support in 2020 (the latest year for which country-level data is available). But it is well below other G-20 members on a per-capita basis – at $111 in 2020 compared with, for example, Saudi Arabia ($1,433), Argentina ($734) and Canada ($512). It also scaled back this support by 12% over 2016-20, while Canada more than doubled fossil-fuel support over that period. The US has the lowest per-capita total out of the G-20 (at $34 in 2020) but provided 57% more of such subsidies in 2020 relative to 2016.
To effectively lead the phaseout of coal and other fossil fuels, G-20 countries must introduce a meaningful carbon price, so that companies and consumers pay for their greenhouse-gas emissions. In total, 12 member countries of G-20 have nationwide carbon pricing. Europe and Canada remain G-20 leaders for robust carbon policies. In particular, prices are close to or far above the level needed to limit global warming to 2C above pre-industrial levels by the end of the century. The World Bank estimates this range to be $40-80 per metric ton by 2020 and $50-100 by 2030. The other G-20 countries with nationwide schemes have an average carbon price of $8/ton and the US, which has several state-level programs, has an average price of $9/ton. Most of these programs are less effective as they cover such a small share of national emissions or offer concessions that are too generous to participants.
The third priority area is to enforce climate-risk disclosure by companies and financial institutions. Policymakers are more loudly than ever voicing concern that climate change poses major risks to financial stability. However, out of the G-20 countries, only the EU and UK have passed laws or regulations to mandate specific, nationwide climate-risk disclosure for investors, while the US has issued a proposal to take this step. Instead, most G-20 governments have only gone as far as launching pilot projects and issuing voluntary guidance documents. These may mark a change in rhetoric and help improve financial market participants' capabilities without being too disruptive for current market practices. But this type of voluntary approach allows institutions to delay action.
Current situation - energy price pressure
In this thematic section the event dealt with the current challenges and the best way to deal with them with pragmatic solutions for the companies.
Energy expert Markus Barella (energy-first) showed the participants the correlations and the development of energy prices and how they are influenced.
All in all, it is now a matter of saving as much energy as possible where this is possible; cutting back production is expressly NOT a solution, because there is still a wide range of energy-saving potential for every company, especially as far as renewable energy is concerned, but politicians are also called upon to act more quickly and clearly, because uncertainty and hesitant politics fuel inflation. In addition, the merit order system could be questioned, at least temporarily, in order to give the market a chance to disentangle itself.
Entrepreneur, die caster and positive thinker Gerd A. Röders from Soltau impressively confirms that many companies are currently struggling to survive, but that this phase, too, will pass. Röders has not relied on state support in his company so far but has pragmatically put all energy-relevant criteria to the test. Together with his people, a consumption methodology was introduced for each individual machine, a changeover to 3-shift operation was made with changes in feeding and a simultaneous extension of weekends.
In the quality area, an optimization of rejects was set up, so that the entrepreneur Röders and his staff can remain positive in spite of everything.
The assessment of the renowned management consultant Johannes Messer and the resulting instructions for action are very similar.
Messer explains that we are currently facing more challenges at the same time than ever before, but that the art now is to turn these challenges into success. E-mobility can also be an accelerator, on the one hand because new competitors are on the market and the struggle for the best production is just beginning. For Europe in general, the die-casting and lightweight construction expert does not see the black.
Europe's advantage, he says, is the best network that has grown up around the world: the best suppliers, the best raw materials, the leading product developers, the best mould making and optimal mechanical engineering.
This constellation contains a preferential quality per se, which must be used consistently, especially now. However, Messer sees a joint approach by OEMs and suppliers as a prerequisite for success, in order to utilize the foundations of the network. He therefore calls for cooperation between OEMs and foundries at the earliest possible stage of the design phase and high speed in implementation.
In the panel discussion with Dr.Thomas Knopp, G.A. Röders, Peter Lutze (ae Group) and Johannes Messer, the participants agreed in principle that this is precisely where things must start.
The criteria for success are quite simple in a nutshell:
Fair customer/supplier relations, cost reduction and scrap optimization, these are the points that the companies themselves must achieve. The panelists also agreed that it is not worth following every short-term trend, but rather to use the right material in the right place with the right process. Peter Lutze was able to give an example of this for his company, the ae Group, which already produces CO² neutrally today. Despite all the optimism and progressive production, there are also challenges that cannot be solved technically, such as the latent lack of personnel.
All the more reason for the foundries of the future to actively present attractive jobs.
All in all, the event organized by Fraunhofer IFAM and VDI offered interesting presentations and an excellent networking platform and impressively showed how important events of this kind are in terms of presence.
The technical contributions were rounded off with an interesting approach by the HA Group on the use of lost cores in HPDC, casting simulation of semi-solid casting (Project Engineering GmbH), coils for electric motors produced in aluminium die casting (Heinzmann GmbH), also with a view to independence from copper as a raw material, and highly efficient wheel hub drives presented by Deep Drive.
The new RGU-FRP UIX interface
With the new RGU.FRP® interface (User-Interface Extended, UIX), you have a portal for editing, visualizing and displaying your FRP® data. The completely newly developed interface is based on the latest MDI technology, which opens up the free arrangement of a wide variety of content for you. This allows you to arrange the content you need according to your needs and optimize your workflow. Upon request the GUI interface is also available in the new FRP® UIX DarkMode.
Single Sign-On
Data security made simple. The single sign-on procedure increases the security of your system, as the password for access to the FRP®.OPTI system has to be transmitted only once. Instead of a large number of mostly insecure passwords, one single and secure password can thus be selected and after a one-time authentication at a workstation, the FRP®.OPTI system is made directly available.
Improved 4K display support
The 4K monitor offers a four times larger work display compared to the Full HD resolution of 1920 x 1080. This gives you more information at a glance. And, thanks to the MDI technology used in FRP®.OPTI, you can place all the content according to your requirements.
Up to date with x64
Release 21.1 is exclusively available as a x64 version. This takes into account the increasing demands of large data volumes, computationally intensive processes and programs, and ensures higher performance.
RGU-FRP Step-Progress-Guide
Achieve your goal step by step with the RGU.FRP® Step-Progress-Guide. In combination with our FRP® Input Sequence Controller, you can guide the user specifically through the process of data acquisition and the respective process status. The workflow of operations is simplified and incorrect entries are prevented. Of course, the FRP® Step-Progress-Guide and the FRP® Input-Sequence-Controller are fully configurable as per requirement.
RGU-FRP®.Responsive OI – FRAMESET 3.0
Get the most out of the information in your FRP®.Online Infosytem. With RGU-FRP®.Frameset 3.0, we provide you with a high-performance system for data preparation, data selection and data visualization. Easy to use and with an extensive range of options for data export. Of course, in responsive design and configurable in many ways.
There are manufacturing benefits too, according to Began. “There is better modeling of performance and it really simplifies the supply chain,” he said. “There is just one piece for that whole weld assembly from a single source as opposed to numerous components, fastener nuts, and rivets coming from different places. You may go to a single supplier from dozens. A lot of those parts they may have been getting from overseas.”
“Megacasting is of utmost importance for the entire die-casting industry,” stated Cornel Mendler, Managing Director of Bühler Die Casting. “Megacasting gives the trend towards structural casting another push by extending the range of applications to complete body sections with the use of the new large Carat solutions with up to 92,000 kN locking force."
Bühler's site states:
“Megacastings reduce complexity in production by enabling between 70 to 100 parts to be replaced by a single die-cast part. These single-piece castings will generally be produced close to the automotive assembly line, which allows for better integration and reduced transport. Aluminum castings have the potential to be almost CO2 neutral when using low-CO2 aluminum alloys and biogas for the melting furnaces. The aluminum that goes into overflows can be remelted directly and reused in the die-casting cell, thereby avoiding transport and recycling. Thinking a step further, the usage of lighter aluminum parts can reduce the energy consumption of the cars over their entire lifecycle.”
Volvo explains the process in a video: “The process goes like this -- molten aluminum is forced into a high-pressure mold. It solidifies as it cools and is then dipped in water to speed up the cooling process. After some laser cutting and quality checks, the parts produced using this process will eventually become part of the floor structure in our new electric [model] range.”
“This process significantly reduces the number of parts produced and allows for greater design and production flexibility,” the video continues. “Megacasting also helps our sustainability ambitions, as it reduces our environmental footprint across production, gives greater potential for recycled content, and reduces the weight of our cars, which in turn reduces energy consumption and improved energy efficiency.”
Reaping these benefits has its hurdles, however. “These high-pressure die casts, they need bigger footprints,” Began explained. “Some require a deeper hole. A traditional foundry floor isn’t big enough.”
Began toured Mercury Marine to see its installation of a gigapress and was astounded. “I remember walking into that room and hearing that this was just for one machine,” he recalled. “Something like that would normally house three machines. The building needs things like bigger doors and higher ceilings.”
Bühler acknowledges this issue on its website. “Such large solutions require proper planning, looking at the entire process, from the ingot to the body shop,” it says. “These large cells, with integrated peripherals, require a well thought-through setup. It all starts with site planning and the set-up of a process for part handling within the die-casting cell and afterward. Also, the thermal management and spraying process, clever handling of the return material, and the integration of the right peripheral devices are key.”
“Especially for such large projects, thinking about the entire die-casting cells from the melting furnace to the handling of the final part is essential,” Mendler concluded. Click through the slide show to see the complexity of this process.
For registration, please contact Mrs Marion Harris marion.harris(at)caef.eu
Registration for the Summit is still possible at short notice for participants from foundries in the European member countries, as are sponsorship opportunities for suppliers and service providers.
EUROPEAN FOUNDRY WOMEN`S AWARD
In Paris, the European Foundry Women`s Award will be presented for the first time. Please submit applications to Tillman van de Sand tillman.vandesand(at)caef.eu
The following rules apply to all candidates making an entry:
Applicant will have either:
- Made a major contribution to the development of their company
Or
- Made a significant contribution to a practical investigation into a system or systems employed in the production of castings
Or
- Made a personal contribution to attract women and girls into the cast metals industry and /or engineering as future experts.
Entries are welcome from individuals or can be nominated by their organisations / company on behalf of the candidates.
Each entry must be accompanied by a paper (or present a short ‘talking heads’ video) of no more than 600 words* outlining the achievement for which they wish to be considered for the award.
(*Supporting information and evidence such as pictures, social media postings, articles and / or videos can be submitted as part of the application in addition to the paper).
The panel of judges within CAEF will decide upon the winner.
All applications and the information supplied will be treated in the strictest confidence and the judges’ decision is final. CAEF reserves the right to publicise the nominees and their exemplary stories in the media only after permission of the applicant.
Please submit your application for the European Foundry Women’s Award to tillman.vandesand(at)caef.eu until 5th September 2022.
We look forward getting to know many inspiring personalities and stories!
“Our research team is working on the project with great enthusiasm. As an innovation partner, it is our aim to guarantee the supply of optimized TiB2 cathodes to create electrolytic cells for manufacturing aluminum and thus make a significant contribution towards reducing TRIMET's CO2 footprint,” says Peter Polcik, Product Development Manager at Plansee Composite Materials in Lechbruck.
High-level industry event
The exhibition will feature more than 100 kinds of products, covering the ferrous, nonferrous and special casting sectors at the 100,000 square meters hall areas. 1300 exhibitors are expected to bring the latest products and innovative technologies to the show, which will welcome more than 100,000 trade visitors to visit and discuss both on site and in the virtual way. At the same time, more than 100 supporting programs will be launched to introduce the industry achievements and connect participants closely.
Highlighted exhibition areas
- Intelligent, Low-Carbon Die Casting Demonstration Zone
- High-end Brand Foundries Exhibition Area
- Large-scale Integrated Die-casting Display Area
- Low-pressure Casting Exhibition Area
- Squeeze Casting Display Area
- Melting Enterprise Exhibition Area
- Investment Casting Exhibition Area
Full exhibits coverage
Non-ferrous castings with thin-walled, high-strength and integrated characteristics, functional high-quality castings, high-performance nonferrous castings of aluminum alloy, magnesium alloy, nickel alloy, titanium alloy; foundry equipments in the whole process, such as melting, molding, core making, cleaning, sand processing and testing; green raw and auxiliary materials; various deep processing equipment for castings...
- High-end, streamlined, high value-added castings
- Covers a whole process for casting production
- Large-scale, lightweight, functional, streamlined, leap-forward progress
- High quality, high efficiency, environmental protection, scientific and technological innovation
- Industrial robots, remote control, 3D printing
- On-site products display combinds with live demonstrations
Industry leaders gathering
In previous exhibitions, many leading domestic and foreign companies have brought with the latest products and technologies. At the same time, many leading foreign exhibitors organized delegations to visit. Like before, the participation of leading companies is still a highlight of this session.
Up to now, there are more than 500 well-known companies from upstream and downstream industries registered for the exhibition, including HA, ABP, FUNUC, XINXING Casting, KAO, XINGYE, LONGFENGSHAN, KOCEL, SQ GROUP, ZIHENG, SFR, MINGZHI TECH, IMF, SINTO, KAITAI GROUP, TAA METAL, NCS Testing, OTTO, WM, NORICAN GROUP, SAVALI, FUJI, INDOCTOTHERM, C.P.C., ELKEM, Yantai Monn Tech. The exhibition has also got attention from foundry industry clusters, foreign pavilions and various industry associations and branches.
Expand business opportunities through various activities
Nearly 100 concurrent supporting programs will be held during the exhibition, such as the 18th China Foundry Association Annual Congress, Award ceremonies for Best-in-Class Castings, Foundry Material and Foundry Equipment Innovation Award, a series of seminars focusing on the hot topics of the industry and the supply chains, new product release, on-site consultation with experts, etc.. It will be a platform to display new products, release new technologies, learn the latest development and industry trend, connect with the old and new customers, and communicate with the industry experts.
For more information or inquiries, please contact: limengmeng(at)foundry.com.cn or visit: www.expochina.cn
Jefferey Zhou, CEO and Founder of
the Chinese Die-Casting Web (CNDC)
Speaking at the occasion, Kamal Bali, President & Managing Director, Volvo Group in India, said, “At Volvo Group, we are proud to be playing a vital role in shaping the future of the transportation industry. India is a home base for the Group and we not only ‘Make in India’, but also design, process, sell and source from India to the world. In line with our global sustainability targets and ambitions, our aim is to create an environment that is safe and sustainable for future generations – while being immersed in advanced technology that goes into making world-leading commercial vehicles. Green Casting has the potential to kick-start a revolution in the casting manufacturing process for a sustainable future.”
Zheng Yun, Senior Partner and
Vice President, Greater China at
Roland Berger
Present at the launch of the Green Castings were Kamal Bali, President & Managing Director, Volvo Group in India; Marc Delobelle, Head of Fossil-free Materials Purchasing, Volvo Group, France; Girish DM, Head of India Purchasing & Group Truck Purchasing, Volvo Group, India; Sriram Viji, Managing Director, Brakes India; along with Parasuraman Ramachandran, Founding Chairman Green Products & Services Council, CII Godrej GBC, and Devendra Jain, President, Institute of Indian Foundrymen.
In the short term, the challenges brought by the COVID-19 pandemic and the supply chain, including battery raw materials and semiconductors, will continue. In the medium and long term, I am optimistic about the overall global automobile market, especially in the scenario-based autonomous driving, intelligent electric vehicles and the digital development of the whole industrial chain of Chinese market.
Cui Yan, Chief Auto Industry Analyst,
Huaxi Securities Co., Ltd
As for the market in the second half of the year, the supply is recovering rapidly. Combined with a policy stimulus, the whole auto industry is very optimistic in the second half of the year while the growth rate will reach more than 20% in the third and fourth quarters. Another focus is the track on the integrated die-casting, which is now in such a just-starting process.
Zhang Xi, Head of Shanghai Sino-German
Industrial Promotion Center
There is a trend that Chinese die casting enterprises are laying out and investing in Europe, especially in the eastern Europe, and the activities are still very frequent.The casting market across Europe is moving from western Europe to eastern Europe and southern Europe. In the current environment, the trend that Chinese die-casting enterprises ‘s offshore investment is quite obvious.
Fang Jianru, General Manager,
Dalian Yaming Auto Parts Co., Ltd
Dalian Yaming is a relatively old enterprise. It was founded in 1952, with a history of at least seventy years by now. The impact of the pandemic is still very serious this year. For example, the original target of of the company for this year is to double that of last year, the double again next year, or double the target for three consecutive years in the Dalian factory, but the pandemic has given us a blow.We have a growth of 100% in the first three months. But by April it was falling back a lot. There are some reasons. One is the impact from the pandemic, or especially pandemic in Shanghai, Changchun and Tianjin. Second is that we also have a lot of exports, exports to European market are affected by the Russo-Ukraine war. I think the impact from the above is very strong. Into June, the domestic market is gradually recovering, but I think the situation in Europe is not so optimistic, and we have not seen a very obvious and a significant growth.
Han Yanqiu, General Manager,
ASC (Tianjin) Auto Parts Inc.
ASC (Tianjin) Auto is a subsidiary of FBG, a private group headquartered in Cleveland, Ohio, USA. It mainly produces industrial products in the OEM aftermarket of the automotive industry. It is a global supplier with a history of one hundred years.We believe that: First, the global economy has been suppressed in the past two and a half years. Although countries around the world, including the United States and China, have implemented active monetary policy, and the money supply is extremely loose, basically the current problem now is the impact of the supply side, mainly the impact of the pandemic. Demand is not stimulated. So in the past a few years, there has been no big prosperity, so there will be no big crisis. Second, if the United States has entered a period of stagflation, and the Federal Reserve is also carefully protecting the market, they are more worried about the collapse of the US market. The Fed is bound to introduce more aggressive policies to maintain economic stability. Third, according to China's economic stabilization conference, Shanghai and Beijing are now basically actively promoting the resumption of business, market, work and production. State Council has resolutely implemented a package of 33 policies in six areas to stabilize the economy. We need to prevent the pandemic, stabilize the economy and secure its development. Fourth, in terms of export, as one of the three drivers of Chinese economy, export plays a very important role in China's economy, and the stable employment of the country cannot be underestimated. So I believe that the Chinese government will continue to introduce some positive policies. So about the future of the economy, I am optimistic about the future exports. We believe in the country and in the country's management ability. But as an enterprise, we will actively respond to it, do a good job in cost control, keep talents, improve the competitiveness of products, ans improve the added value of products.
Guo Wujun, Senior Deputy Chief Engineer,
Changan Automobile New Energy Vehicle
Technology Co., Ltd.
Changan Automobile has passed the evaluation of the national 863 Project since 2001, and spent five years to do technical research. At this stage, the technical preparation was completed. after another two years, in 2008 the company enter industrialization promotion stage. From 2009 to now, it is the market operation stage of the company. Chongqing Changan New Energy Vehicle is an automobile enterprise to enter the field of new energy vehicles earlier. The future product platform layout: small platform is urban mobility scooter, middle platform is economic family compact models, high-end quality experience and high-end models. We know that the integrated body is a number of traditional body parts, designed into one or more parts, and then connected to form the whole body. Its advantages are to improve the platform evolution, improve the performance, improve the manufacturing accuracy, shorten the product research and development cycle, improve the space utilization rate, and shorten the manufacturing chain. For new energy vehicles, there is a great potential for development. I believe that integrated die casting is a big trend, and in the future this will be used in high-end cars. For low-end products, with the breakthrough in materials, I believe that there will be space and opportunities for development.
Cai Zifang, Chair, Shunjingyuan Precision
Casting (Shenzhen) Co., Ltd.
Hong Kong enterprises face a big problem, the damage from this wave of pandemic is big, but the impact from the US sanctions and from the industrial chain relocation is bigger and many foreign enterprises moved out of China. As Europe and the United States market accounted for nearly 70% of Hong Kong enterprise’s business, the situation is very serious. What is the problem right now? you will either move out of Chinese mainland to continue our European and American business, or you will invest in Europe, or set up factories in Latin America, or go to run factories in Southeast Asia, we all face a big dilemma. We believe that a large number of purchase orders from Russia are pouring into China, including equipment, machinery and electronic products, especially the parts of maintenance consumables, etc. They are in urgent need of emergency procurement from China. The whole industrial chain of Russia needs everything, also another important business opportunity for Hong Kong enterprises. Although the difficulties in Hong Kong are much greater than those in inland China, I am optimistic and believe there is in other way to work out. After all, we have been doing business with Europe for more than 100 years, and Russia's foreign trade is also concentrated in Europe. It is easy to achieve mutual trust when our business philosophy and business rules are much the same as those of Europe and the United States.While it's not easy to change the structure and direction of your business, you always have to change it in the changing pattern of this centennial history.
Lu Min, General Manager,
Asia Pacific Region of Bühler (China)
Machinery Manufacturing Co., Ltd.
It is an issue of industrial transfer. Bühler has some countermeasures in this regard. Judging from the global economic development in the past 20 years, the industrial transfer has always been taking place. From my personal observation of the global die-casting industry, especially in the Asia-Pacific region, in fact, China's die casting industry has reached a very high height in the world.We may not be able to reach the top in some aspects, but the high-end part of the die-casting industry is very close to foreign advanced levels, not only in scale, technology or quality, especially in the area of scale and quality. These years have seen very rapid development, especially in the recent five or six years. I once communicated with a senior executive of Hartman, who said that the same company works in Germany and then produces the same products in China, and obviously the company's customers have higher requirements for the parts in China than those in Germany. Therefore, it can be seen from another perspective that the improvement of technology and quality of our Chinese industry is very fast.We don't need to worry too much about the industrial transfer.The former low-end industries of Europe have moved to China. Now the low-end is moving to Southeast Asia or South America, or Turkey, or even to the Indo-Pakistan region. China is the largest car market, I don't need to worry too much. If you want to move the whole industry, or really want to do the industry, it is very important to be close to the industrial chain. On the contrary, in the past decade, China has established a whole and truly high-end industrial chain.So the advantages of China's die-casting industry will continue to grow. Not only does China have the market, but has established a talent mechanism and technology mechanism in the Chinese market.
The ALUNEXT business unit operates a small foundry on its premises for the trial series production of HPDC, LPDC and LPF. Here there are die casting cells and a brand-new machine for low-pressure forging in use in the actual foundry. Three HPDC machines from 1900t to 3000t, one LPDC machine and two LPF machines.
As a mold maker, COSTAMP is always at the forefront, together with its customers, when it comes to the possibilities and implementation of projects for light metals in HPDC or LPDC. Customer orientation and thus process technology and economic efficiency therefore have top priority.
Based on long experience and cooperation, technologies have also been developed that give the company a certain unique position. One example is the PiQ² simulation software, which was used to develop a proprietary filling simulation for HPDC, which has met with great interest in the market. Castle, the software application by PiQ² is developed especially for HPCD in aluminum, magnesium and zinc. We will be happy to present PiQ² and the Castle software in a separate article at another time.
Another example is the "Puzzle die" project, which leads to an increase in the economic efficiency and service life of dies that deserves the highest attention.
It is not entirely coincidental that the COSTAMP Group also plays a leading role in the field of giga tools.
As company boss Marco Corti, together with Alberto Ratti and Andreas Kant, proudly informs us, COSTAMP is one of the few suppliers of giga tools for the 6000 - 9000 ton die casting cells.
Of course, this requires the necessary space and COSTAMP will invest heavily in this area.
In combination with the strong technological basis, a highly motivated team and the most modern equipment, economic solutions are to be achieved with the greatest proximity to the customer, which meet the great challenges of the time. COSTAMP seems to be well equipped and that is why the management is relaxed and optimistic about the future.
Visit COSTAMP also at the EUROGUSS Hall 7-742
COSTAMP at a Glance
COSTAMP HPCD
Dies for High Pressure Die Casting
This is our “core business”
Dies for aluminum and magnesium parts
Customer base: 95 % automotive sector
Powertrain, EV and structural components
Giga tools
Puzzle Dies
Try-outs and production ALUNEXT
Extensive equipment for process simulation
So how did he make them? Using the lost wax casting process, but with PLA rather than wax. After designing the shape in CAD, Seth 3D-printed models of both the nut and bolt.
"Then I coated the models 10 times with a ceramic material called Suspendaslurry," he writes. "After the ceramic shells were completely dry I placed them in my kiln and melted out the PLA plastic.
"At 1500 degrees Fahrenheit the ceramic shells became vitrified, turning into a ceramic that can withstand the heat of molten bronze. I melted the bronze in my homemade keg foundry furnace and then poured the liquid metal into the ceramic shell molds."
Here's a look at his process:
Individual application of the release agent to both mold halves
4 freely programmable axes
For die casting machines from 4500 t clamping force
Stroke lengths of up to 4000 mm possible in both axis directions
Up to 10 spray and blow circuits per side
Several different release agents applicable
|
|
Split horizontal and vertical axes
Weight of the mass to be moved reduced by half
Greater speed and dynamics
Lower load on the drives
Low energy consumption
Divided axes allow the release agent to be applied individually to both mold halves
Release agent application at the same time as the cast part is removed
possible on the fixed side
Significant reduction in cycle time
User-friendly and robust drive concept with high load reserves via toothed racks and maintenance-free toothed belts
Vertical axes in a compact telescopic design
Use of reliable and proven components
Feedback for a further reduction in power consumption
Control valves, quantity measurement, etc. are installed close to the spraying technology
This results in short and repeatable switching times of the spray circuits
Precise measurement of release agent quantity
Project-related design of the spray head and shape-related division of the spraying and blowing circles
Spray heads with 10 spray and blow circuits per mold half
1 continuous spray and blowing circuit provided over the entire length for 2nd release agent
High operational reliability as well as short and precise spraying times thanks to membrane control
Release agent can be applied while driving
The next EUROGUSS will be held in Nuremberg from 8 to 10 June 2022.
For all details please go to: www.euroguss.de
Interested in more NF-Lightmetal and die casting related information?
Please check out Event-Connector for EUROGUSS 2022.
Assembly consisting of three die-cast parts / housing-cover-front
Dipl. Siegfried Müller GmbH & Co. KG
Zinc category: 1st place
Dimension (L x W x H): 100 mm x 94 mm x 29 mm
Weight: 235 Gramm
Alloy: ZP5
Description:
n.a.
Design, casting and molding requirements:
n.a.
Reasons for manufacturing in die casting:
Good shielding for electronic components made of zinc / high design possibilities with low manufacturing costs / high-quality surfaces without additional processing steps
- Well over 1000 conveyors in use (SP 25 and further development SP-HL)
- Continuous conveyor for bulk materials
- Small installation space, high conveyor capacity
- Gentle conveying and high energy efficiency through continuous conveying
Pneumatic conveying of bulk materials has many advantages compared to mechanical conveying methods, such as tube chain conveying or transport with conveyor belts.
Pneumatic conveying systems are clean and require little installation space and maintenance. Only the costs for generating the conveying air are disadvantageous. This makes it all the more important to exploit potential savings!
In a classic conveying process, the pressure vessel conveyor is pressurised with compressed air (ventilated) and the bulk material is conveyed through the conveyor lines, e. g. into a silo, by means of compressed air. For refilling, the conveyor and the entire conveyor line are completely deaerated, i. e. with each conveying process the entire conveying system is depressurised to ambient pressure and the conveying process is completely interrupted. With each new conveying process, any remaining bulk material in the conveyor line must be set in motion again.
Thanks to their design and their elaborate construction, the robust, worldwide used conveyors of the SP-HL series of KLEIN Anlagenbau AG enable an energy-saving, continuous conveying that is gentle on the bulk material and minimises wear on the system.
What exactly is the secret of the great success of the SP-HL series of KLEIN Anlagenbau AG?
The basic mode of operation can be outlined in a few words.
The details of the constructional design represent the comprehensive specific know-how of KLEIN Anlagenbau AG.
The core of the principle is a deliberately small pressure vessel in combination with a tight closing valve between the pressure vessel and the conveyor line. The small size of the pressure vessel results in a fast conveying cycle sequence, as only little time is needed for filling and delivery of the material into the conveyor line. As soon as the pressure in the conveyor line is exceeded during the ventilation process, the valve opens automatically and the bulk material is discharged from the pressure vessel into the conveyor line. As soon as the pressure vessel is emptied, the closing valve closes, the pressure vessel is vented and new bulk material flows into the pressure vessel. Owing to the closing valve, the pressure in the conveyor line is kept, and because of the short cycle time further bulk material enters the conveyor line after seconds. This way the low-wear and energetically favourable continuous conveying can deploy its economic advantages.
The pressure-litre product of the pressure vessel has deliberately been chosen so small that the periodic inspections of the pressure vessel can be carried out by "competent persons" within the company. Testing institutes such as the TÜV are not necessary here.
This also saves time and good money!
According to customer requirements, the SP-HL is available for different flow rates in DN 80, DN 100 and DN 125. For a maximum delivery rate, a tandem version for conveyor line diameters of DN 125 is available. In this case, two SP-HLs are delivering alternately into the same conveyor line in temporarily staggered sequence, thus contributing to further optimising the conveyor rate.
Figure 1 shows the comparison of conventional KLEIN conveyors with the SP-HL.
Double-digit growth in all divisions
Orders received increased by a total of 27.7% at Group level to around €3.6 billion (2020: €2.8 billion) and sales revenues by 27.7% to €3.3 billion (2020: €2.6 billion). Although global supply bottlenecks and increased material and logistics costs slowed down the positive development, especially in the second half of the year, EBIT rose to €61.8 million (2020: -€113.2 million). The EBIT margin increased to 1.9% (2020: -4.4%). KUKA’s China business in particular saw strong growth, with revenues 48.4% higher than in 2020 and orders received up 39.0%. In the Chinese robotics market, KUKA also made gains in new sectors such as electronics.
KUKA is also supporting more and more automotive customers in the global trend towards e-mobility as they make the transition to new drive systems, for example with automated production systems for battery modules. Demand for electric vehicles is growing, especially in China and North America. Accordingly, orders received by KUKA Systems, the Group’s systems engineering division, rose by 37.3%, driven by strong business in North America.
And with strong demand in e-commerce and the trend towards automated logistics solutions, KUKA’s logistics specialist Swisslog increased sales revenues by 23.4%.
Automation conquers new areas
“Our automation and logistics solutions are in increasing demand among small and me-dium-sized enterprises. Companies in the consumer goods and food industries are also turning to robotics to an ever-greater extent,” said Peter Mohnen. “Our technologies can provide support in a wide variety of areas across all production steps.” With the expanded robot portfolio featuring models such as the KR DELTA, as well as new vari-ants like the KUKA “Hygienic Oil” robots for food production, KUKA offers the right solutions here.
“Even though we will need to address supply bottlenecks, material shortages and higher costs in the coming months, we see a strong tailwind for KUKA – and we will take advantage of this tailwind,” stated Peter Mohnen. “Our goal is the leading role in robot-based automation by 2025. Our focus here is clearly on driving technologies and innovations forward at an intensive pace. To this end, we will invest around 800 million euro in research and development by 2025, more than ever before.” The key to massive growth is an overarching portfolio and regionally tailored products and solutions for individual markets, especially in general industry. “KUKA will benefit from this growth strategy and our technological orientation in the long term – at all locations around the globe.”
Did you know, that on the new ESM die spraying machines from Wollin, the flow sensor is installed directly on the horizontal unit of the machine? This sensor automatically tracks the flow of the used release agent, air or concentrate – reliable and fully automatic.
With the flow control tool you can e.g.:
- track the automatic flow measurement per cycle (and spray circuit)
- track the target / actual comparison of flow rate values
- get notified in case of deviation above the permissible value
- signal a cycle stop in case of deviation
… and much more.
It is the fourth digital tool to be launched by Wheelabrator, all designed to tackle the biggest challenges and cost drivers of running shot-blast equipment.
Heinrich Dropmann, Senior Vice President Global Wheel at Wheelabrator explains: “Most blast machine operators currently have no easy way of tracking their machine’s operating mode. They don’t have an overview of periods of downtime or idle time and their causes, whether it’s faults, delays at the point of loading/unloading, maintenance or breaks.
That means they can’t compare the efficiency of different product runs or shifts, or pinpoint where something’s not running smoothly and why. Our new tool gives them instant access to all of this information to identify bottlenecks, reduce idle time and operate the machine ever more efficiently and productively. It can be retrofitted really easily for an instant performance boost.”
To deploy this or any of its other digital tools, Wheelabrator can digitally enable virtually any type of shot-blast machine, new or old, using it’s NoriGate data gateway and Monitizer | DISCOVER software.
Research Project Highlight – Big Data
We are working in an era where manufacturing is undergoing significant changes. Specifically, the nexus of Artificial Intelligence (AI) and metal processing which has opened a vista of opportunities that could not have been realized previously. Researchers at ACRC and at UCI’s Hub for manufacturing – Industry 4.2TM have been pursuing a set of ambitious projects in this domain. We feature, specifically, a project addressing data (or lack of data).
To use AI and machine learning for optimizing manufacturing processes, the first step is to get the data right. The amount and quality of the data collected is key to good data driven modelling of these processes. Thus, it is important to keep track of the quality details when collecting and aggregating the siloed datasets. Data quality management plans are at the core of Industry 4.2TM and smart manufacturing in the digital transformation age. Data management plans comprise the entire lifecycle of the data from collecting data, integrating the different sources into a coherent format, data normalization and storage to analyzing the data for instant plant action as well as offline. Data cleansing and pre-processing are pre-requisite to transform the raw data collected into knowledge via such a lifecycle. Due to the diversity in the types of data collected at the foundry, for example, data in different formats, at different levels of granularity and time periods leads to datasets that are siloed, noisy and incomplete in nature.
The focus of our work is on the application of deep learning methods to treat such data quality challenges and to develop data-driven models and obtain insights into the manufacturing processes. This work addresses different dimensions of data quality which are essential for materials processing and manufacturing companies interested in machine learning (as featured in this figure). We provide solutions for these which can be easily incorporated into the existing frameworks of the foundry. Moreover, the models developed enable the manufacturing companies to do machine learning for applications, such as identifying primary drivers of defect formation, anomaly detection, part quality prediction and predictive maintenance, even when a gold standard data management plan is not readily available.
Click here to learn more about this project and our other groundbreaking research.
Source: www.acrc.manufacturing.uci.edu
Statistics: Largest aluminium producers worldwide by production volume in 2020 (in million tonnes) | Statista
You can find more statistics at Statista
Since China is also having problems, the price of aluminium could rise significantly further.
Last week it was already reported that Trimet is cutting back its production in Essen due to the sharp rise in energy prices.
The price of aluminium is currently just under $3,500 per tone.
Source: Guss-Geflüster
For the concentrate, Wollin are using a flow meter that determines the flow volume of liquids with a non-contact measurement approach for conductive and non-conductive liquids.
All process values are either shown on the display of the flow sensor or, if paired with the PC3 control, on the display of the controller. With the PC3 control, the minimum and maximum quantity of release agent in liters can be defined for each circuit
For robot solutions, a stand-alone control device with an S7 control with up to 5 sensors can be integrated into the robot spraying process – 1-4 sensors for release agent and 1 sensor for concentrate.
The conclusion is simple: make your spraying work flow more efficient, economical and flexible by knowing how much release agent, air or concentrate per production cycle or spray cycle you are using.
Interested and want to know more?
Further information on Wollin’s solution to flow control can be found here: https://www.wollin.de/en/technology/industry-4-0/flow-control.html
The next EUROGUSS will be held in Nuremberg from 8 to 10 June 2022.
For all details please go to: www.euroguss.de
Interested in more NF-Lightmetal and die casting related information?
Please check out Event-Connector for EUROGUSS 2022.
Cross Car Beam HUD / Instrument Crossbar / Legal Entity
GF Casting Solutions, Schaffhausen
Magnesium category: 1st place
Dimension (L x W x H): 508 mm x 300 mm x 1523 mm
Weight: 3.480 gram
Alloy: AM50
Description:
Highly stressed component which must also offer very high stiffness under dynamic loads in order to exclude vibrations, e.g. in the area of the steering wheel or the head-up display. In addition, the component must allow a high degree of deformability (e.g. in crash behavior).
Design, casting and molding requirements:
Representation of the necessary requirements in a restricted installation space, which meant that the cross sections in the casting had to be designed flexibly. The ribbing was designed to meet the stresses, which was continuously evaluated by simulation in terms of mold filling and solidification behavior. Integration of as many different functions as possible in the casting (attachment of add-on parts, integration of brackets, etc.).
Reasons for manufacturing in die casting:
Due to the highly restricted installation space, die casting offers the possibility of optimum utilization of the free spaces and thus a design that is more suitable for the stresses. In addition, the use of magnesium makes it possible to achieve the high stresses in a low weight.
One-piece upper shell of a die-cast rear axle carrier
Albert Handtmann Metallgusswerk GmbH & Co. KG
Aluminum category: 1st place & audience award
Dimension (L x W x H): 1.260 mm x 670 mm x 390 mm
Weight: 19.300 gram
Alloy: Al Si 10MnMg
Description:
High functional integration with connection points for the mounting of control arms, struts and stabilizers, the electric drive unit and for fastening the parts composite to the vehicle body.
Worthy of particular mention is the creation of a closed cavity by means of a hollow profile integrated into the casting process which, in conjunction with the topology-optimized design of the upper shell, meets all strength, stiffness and NVH requirements in the die casting process. The integral design of the TOP-HAT avoids complex joining processes and eliminates various individual components.
Design, casting and molding requirements:
In the casting and mold design of the 36to DGF with a contour slide, supported by various simulation software, the focus was on the following features: optimum filling over the entire component and in part local compaction of the critical functional areas, optimum vacuum-assisted venting of the cavity, material reductions of thick-walled areas taking into account the strength requirements, optimization of the processing contents and contours, use of special mold technology such as JetCooling integrated in the squeezing area and the fixing of a long cavity-generating insert to improve the NVH behavior.
The basis for this was provided in advance by: design space investigations, various fatigue analyses and calculations, topology optimization, stress and distortion calculations, development of a centering and fixing concept for the insert, and consideration of thermal expansion and shrinkage.
Reasons for manufacturing in die casting:
The one-piece die casting design eliminates complex assembly steps (e.g. welding processes). Various parts/components could be eliminated. Mechanical processing can be carried out in a single clamping operation. The insert molding technique achieves weight reduction with the same or higher component performance. Thus, die casting has turned out to be the optimal and most economical process for us.
Most companies already collect data with partly different systems, it depends on the level of integration and (data) transparency!
What if companies are already busy collecting data or working with SAP in different areas? No problem, says Ronald Kreft, that is quite normal, we always look at what is feasible and what can be integrated.
These are the daily requirements of the company, which has been globally active for almost 15 years. In the meantime, there are a lot of real success stories and we are looking forward to presenting one or the other practical example in our own articles in the future.
It's all about precise starting points if you're thinking about getting in touch with RGU staff, because RGU GmbH and its subsidiaries and partners, with their experience in both foundry and IT worlds, offer advice at your eye level.
This results in transparent and efficient solutions that are written in the language of the industry and in which the process participants in the foundry find themselves. Software implementation always involves feasibility and efficiency analyses in close cooperation with the aim of making the processes more productive and economical.
RGU, these three letters originally stand for the German expession of „Computer Aided Corporate Controlling and Consulting“ ("Rechnergestützte Unternehmensführung und Beratungs GmbH"). The company name has everything you need and the FRP® system is ONLY for foundries, what else do you want?
We have posted a first white paper for you in our white paper section, we will provide comprehensive information on the topic in a series of 6 editions, read the current part 1 https://www.foundry-planet.com/whitepapers/webinars/whitepapers/show/collecting-data-in-the-casting-process/
Figure 1: Conveying capacity of different conveyors depending on the conveying distance L*.
Figure 2 impressively shows the energy savings thanks to the continuous conveying with an SP-HL. Particularly for long conveying distances, energy savings of up to 50 % are achieved (energy consumption of a conventional T-conveyor in relation to the energy consumption of an SP-HL conveyor).
Figure 2: Compressor drive power of different conveyors depending on the conveying distance L*
The KLEIN SP-HL - Better buy "THE ORIGINAL" from KLEIN Anlagenbau AG –
In the technical centre of the new building of KLEIN Anlagenbau AG, conveying distances up to 140 m can be realised immediately. Here, the most diverse bulk materials of our customers as well as different conveying methods are tested and optimised with the conveyors of KLEIN Anlagenbau AG.
Figure 3: New building of KLEIN Anlagenbau AG with technical centre
The KLEIN SP-HL - THE ORIGINAL
- unbeatable in energy efficiency and functionality -
- unrivalled in price and quality -
Phillipsburg pipe maker seeks higher limits on air pollutants
McWane Ductile-New Jersey in seeking a new state air quality permit proposes to increase certain hazardous air pollutant emissions limits from the baghouse filters on the Cupola Furnace, Melt Center and Zinc Coating systems at its 183 Sitgreaves St. plant in Phillipsburg.
Units are pounds per hour. * The current permit does not have a pounds per hour limit. ^ As a comparison, the proposed Cupola Baghouse cadmium emission rate is 0.0033 pounds per hour. The proposed Zinc Coater Baghouse cadmium emission rate, therefore, is approximately an order of magnitude below the Cupola Baghouse's emission rate.
Company representatives stressed that they’re not looking to increase production at the plant, which melts scrap metal to produce ductile cast iron pipe ranging in diameter from 3 to 24 inches and which is used to carry drinking water. The foundry, which has about 200 employees, operates 220 to 230 days a year, said Vice President/General Manager Keith Mallett. That breaks down to about 10 hours a day for four to six days a week, according to Steve Shambeda, the foundry’s environmental health and safety director.
“This is the busiest year we’ve had,” he said Wednesday night. “... The changes that we’re making, we don’t plan on increasing beyond what we are doing right now.”
Seen from the air on Wednesday, Feb. 16, 2022, McWane Ductile-New Jersey at 183 Sitgreaves St. in Phillipsburg is looking for New Jersey Department of Environmental Protection approval to renew and modify its air permit, to allow increased emissions of certain hazardous pollutants. A public hearing was held Wednesday, March 9, 2022, at the Phillipsburg Free Public Library.
Shambeda sought to explain that even if the pollutant levels are raised, that doesn’t mean the foundry’s emissions will reach those limits. Rather, the company is looking for increased flexibility to account for “natural raw material variability” in the metals that the foundry melts.
“The material that’s coming to us is changing,” Mallett said. “We melt a lot of chopped-up cars and chopped-up buildings. That’s what we melt.”
“So that means the air I breathe on Firth Street is going to change,” replied Flynn, one of the residents on hand Wednesday.
Shambeda said that stack-testing at the foundry is conducted by a third-party company and monitored by the NJDEP based on higher-than-normal operations. At normal rates, the higher pollutant caps would not be necessary, he stressed, likening normal to 65 mph while the testing is done by pushing the foundry’s operations to 80 mph.
Mallett said the testing is done “at a worst-case scenario.”
“If we ran at the normal standard speed of 65 mph, which we run every day, we would have no problem and there would be no need to ask for emission limit changes,” Shambeda said. “The DEP in trying to make sure that we don’t emit a lot of pollutants asks us to run at 80 mph for the test, which is not a standard thing.”
The emissions passed every test last year, he said, “but we’re very close. ... It’s close enough that an excursion or a spike could happen depending on the scrap material.”
Carol A. Staten, who lives in nearby Bloomsbury, suggested McWane Ductile do a better job of analyzing the scrap metal that comes in before melting it down. Mallett responded that he’s unaware of equipment that can do that on a scale the company would need.
Carol A. Staten, of Bloomsbury, gestures while speaking to Steve Shambeda, in red, who is the environmental health and safety for McWane Ductile, and other representatives of the company during a meeting Wednesday, March 9, 2022, in the Phillipsburg Free Public Library concerning an application to increase the caps on hazardous air pollutants from the foundry in its New Jersey Department of Environmental Protection Title V Air Operating Permit.
“If you’re spending all this money, you’re going in the wrong direction,” said Phillipsburg resident Patrick Petroll. “The air should be cleaner.”
Petroll read an account of the U.S. Department of Justice’s prosecution of environmental crimes by Atlantic States, the company’s name until 2015, that led to prison sentences for four managers and an $8 million fine.
“You guys have a really bad track record and it’s hard to trust you,” he said during the meeting hosted by the Phillipsburg Free Public Library in its “Community Room Furnished by Atlantic States.”
Sherry Hoffman spoke of toxic fumes that used to blow from the foundry into her Pursel Hill home in town, forcing her to close the windows.
“It was much worse many, many years ago,” she said. “We’ve lived here for 22 years. And it’s been better for the last maybe 10 years or so.”
Mallett explained that the current baghouse system designed to trap pollutants was installed in 2004 at a cost of $10 million, and speculated emissions at Hoffman’s home were worse under the old system. Shambeda said the new system cut actual emissions from the foundry’s stack by 90% to 99%.
Now, however, the company says it wants to be able to increase its Cupola Furnace baghouse air pollutants like arsenic by 100%, nickel by 400% and chromium by 900%. The proposed emission limits from the plant’s Zinc Coater baghouse would allow for corrosion-control coating of pipe to meet customer demands, while increasing that portion of the plant’s cadmium emissions by 2,127.3%, according to figures from the company. (McWane Ductile notes that as a comparison, the proposed Cupola Furnace baghouse cadmium emission limit is 0.0033 pounds per hour, up 57.14% from the current 0.0021 pounds per hour, while the proposed Zinc Coater baghouse cadmium emission limit of 0.00049 pounds per hour — up from 0.000022 pounds per hour — is much lower than the Cupola Furnace baghouse’s emission rate.)
Karen Kelly-Stratos, who lives on Sitgreaves Street and went from complaining about foundry emissions to serving as chairwoman of the McWane Ductile Community Advisory Panel, stressed the benefits the more than century-old company offers to the town. Residents have to understand this is a foundry, she said, but at the same time McWane Ductile has been very cognizant of neighbors and supportive of the community through donations and scholarships beyond the employment it offers.
“They’re one of the only businesses that’s going on in town,” she said. “We would like to preserve it.”
Said one resident, who didn’t provide his name before speaking: “We can’t go on the way we’re going on, sacrifices maybe have to be made. I know 200 people are working with your company and that’s great, they’re able to raise their families to support themselves, you’re helping to support the community. But as a number of people brought out, there would be nobody here at this meeting if you … were to go back the other way and restrict the amount of pollutants that you’re putting into the air.”
Phillipsburg Town Councilman Lee Clark attended the meeting, as did council President Harry Wyant Jr., with Mayor Todd Tersigni noting his and Councilman Keith Kennedy’s attendance. Clark works for the NJDEP as a Green Acres project manager.
“I’m not in favor of increasing the limits,” Clark said. “I know we’re saying that it’s still within state ranges of safety but I still have to talk to families every day who are concerned about this. Ever since they saw this come out on the news, their first line of thinking was, ‘What’s the safe level of arsenic to breathe in? What’s the safe level of zinc to breathe in? What’s the safe level of lead to breathe in?’ When I look into their eyes I can’t honestly answer the question because what’s a safe level of these toxic chemicals to breathe in? I just don’t see it.”
Several residents who spoke acknowledged the benefits McWane Ductile offers to the Phillipsburg area, including Flynn from Firth Street.
“Thank you for everything you do for the community, really,” he said. “It’s well appreciated — other than ...,” he paused, apparently alluding to the emissions. ”I understand,” Mallett replied. ”Other than,” Flynn repeated. ”And I’ll just say, we hear you. We hear you,” Mallett said.
Source: www.lehighvalleylive.com
Author:Kurt Bresswein may be reached at kbresswein(at)lehighvalleylive.com
A different way to sell, a new business model
Sales people, highly skilled in the technical aspects of their products, have not been able to visit existing and new customers globally as they were used to do before COVID-19 started.
So the many “face to face” meeting, onsite visits and technical negotiating carried on at customer site had to be replaced with online calls, virtual simulations, zoom meetings and so on.
Despite this abrupt change in the “selling method” Lianco sales team had to face and secure orders in several countries around the world, thanks to its deep knowledge of the grinding shop needs and capability to properly satisfy customer expectations.
Lianco after sales solution: a network of service partners
Once the order is secured and the machine built at the HQ the next challenge has been the installation and commissioning at final destination. Due to pandemic restrictions and quarantine companies had to face the impossibility to send technicians from HQ, option that in the past has always been a “must have” for the proper installation of high end equipment.
To avoid unacceptable delays this scenario has imposed companies to find a new business models.
Lianco organization found out its own solution to this unprecedent issue in the roots of the sales team, who developed along the years a strong network of relationship with service partners strategically located where the market is. This unique ally, forged through many realized projects and many years of teamwork, started proving his unique added value since first sold grinding machine installation started in 2020.
The challenges make grow many local service teams
Since that the Lianco partners have been operating in several places around the world affected by the pandemic, from Brazil to India, from Mexico to central Europe.
CNC grinders and robotic cells have been installed and commissioned by experienced local people remotely supported 24/7 by the HQ, with no need for technicians flying out of the factory.
The many challenges faced by the service teams (time zone difference, language barrier, new equipment) did not stop them from completing the assigned task. This experience is just at the beginning but with the several new installations planned for 2022 surely will grow fast and allow Lianco to offer a comprehensive service to its valuable customers.
According to the German Automobile Association, despite the chip shortage and the global pandemic, Germany has seen a 73% jump in electric vehicles sales in 2021 compared to 2020 figures, contributing 26% of the overall sales of passenger cars.
The German governments innovation premium offered as part of the subsidy on the purchase of electrical vehicles has undoubtedly boosted sales of passenger cars, however this incentive expired at the end of 2021.
Prasad adds: “Germany already has one million electric cars on the road. Half of these are BEVs and the rest are PHEVs. Whilst the inclusion of PHEVs in the count towards Germany’s EV target will boost the numbers however, they will also increase emissions from their IC engines which may affect the country’s timings on reducing greenhouse gas emissions from the transport sector by 2030.”
The Die Casting Dashboard also enables the comparison across die-casting machines and plants, so production staff can quickly see areas for improvement.
At the same time, inputs from each machine can be displayed centrally on any device, 24/7, enabling comparison between machines, shifts, die programs or facilities.
Accurate Downtime Analysis based on root cause data
Downtime Analysis, a comprehensive failure analysis tool, is also available, providing root cause reporting from each die-casting cell.
Sector backs change of date
The honorary sponsors and partners of EUROGUSS are backing the change of date. Hartmut Fischer, the Chair of Verband Deutscher Druckgiessereien (Association of German Die-Casting Foundries, VDD), is looking to the future:
“Every second year, EUROGUSS is THE event for the die-casting industry. Exhibitors and visitors alike have always been pleased to catch up and interact at EUROGUSS, and see the latest trends, including the wealth of information that the VDD’s Die Casting Conference has to offer. But the fourth wave of the Covid-19 pandemic would make it unreasonable to hold it again in the short term; we would have to be prepared to cancel at short notice based on government requirements. In the die-casting industry we need the interaction offered by EUROGUSS, and we are looking forward with optimism to gathering on the new dates in early June."
Timo Würz, General Secretary CEMAFON (The European Foundry Equipment Suppliers Association), emphasises: “Based on the current infection situation, adhering to the original schedule for EUROGUSS would have implied incalculable planning uncertainties for exhibitors and visitors."
The change of date is the right thing to do, and is the only opportunity to ensure we get the high-quality event that visitors and exhibitors at EUROGUSS are used to.” Martin Lagler, Director Product Management & Marketing, Bühler AG, believes postponing EUROGUSS will offer major opportunities: “Given the present circumstances I welcome the fact EUROGUSS is being postponed. The later date will offer the ideal conditions for the entire die-casting industry to interact in person, and for spontaneous meetings between various partners, customers and suppliers.”
Endorsement for the decision also comes from BOHAI TRIMET Automotive GmbH. Managing Director Andreas Kiebel comments: “As long-standing exhibitors at EUROGUSS, we support the decision to postpone the event. Even if the industry urgently needs the personal contact between its members and with the public, we are in favour of nurturing this interaction once again in June under more relaxed circumstances.”
The next EUROGUSS will be held in Nuremberg from 8 to 10 June 2022.
For all details please go to: www.euroguss.de
Interested in more NF-Lightmetal and die casting related information?
Please check out Event-Connector for EUROGUSS 2022.
Much of the cost of sales for foundries lies in material costs. Identifying and rectifying defects in real-time is a simple yet productive method for increasing OEE (overall equipment effectiveness). Reducing waste through AI technology for metal casting processes can be the difference between growing margins and shutting down operations.
AI in metal casting presents opportunities for cost optimization allowing manufacturers to streamline operations and increase revenue. AI technology for casting processes, enables to quickly learn from factory floor data to provide insights, predictions, and identify trends.
What’s more, AI for casting is vital in preventing costly defects and avoiding operational inefficiencies that hurt manufacturing productivity.
The Problem: Excessive Metal Scrap Waste
Scrap reduction use cases have huge ROI implications and are very likely prevalent on your casting lines. HPDC, LPDC and gravity casting are popular casting methods because they provide excellent dimensional accuracy and smooth cast surfaces.
Any casting defects due to blowholes, low mold temperature, or low pouring pressure will lead to lower strength components. Reasons for scraping can be manifold, and every bit of waste signifies a loss of time, raw material, and end product. It's becoming increasingly important to identify defects and their causes in order to improve functionality, production quality, and yield rates.
Accurate analysis, measurement, and evaluation are required throughout the production process to prevent defects. And this includes controlling for factors such as machine malfunction, human error, the miscalibration of assets, plus improperly maintained production lines. If you can't measure it, you can't remedy it.
To achieve operational improvements, foundries must gain control over the vast amounts of data produced on factory floors. There's a need to establish a comprehensive, data-driven solution to optimize casting processes.
In order to reduce waste, it’s imperative to predict where scrap is likely to occur and why that’s happening. Doing so will provide a complete picture of what’s happening along the lines and the underlying causes of product quality issues.
Often, interpreting operational data to diagnose specific issues requires the analytical skills of a skilled technician. However, bearing in mind how large the data sets can get, there's a considerable need for sophisticated AI in casting solutions that can interpret disparate data to provide a real-time, accurate picture of manufacturing processes and operations.
The Solution: Tvarit’s AI-Enabled Scrap reduction solution for Metal factories
A bigger picture means better decisions, and this is where the easy to use Industrial AI Platform comes in. These hybrid AI models complement human capabilities with scrap reduction analytics with the aim of reducing disruptions and optimizing resource utilization through its AI and metallurgy based algorithmic platform. In addition, they leverage machine learning to continuously gain knowledge from casting process data.
A few building blocks constitute this tool. At first glance, the cell performance can be interpreted via “uptime” and “downtime”. Additionally, the most critical downtime causes are ranked for frequency or duration. Maintenance experts and technologists can then analyze each category of technical issue and define proper counter measures. Regularly using Downtime Analysis can help to effectively increase uptime.
Oudi Zhao, Product Manager Bühler Die Casting says: “Data visualizations provide instant information that’s easy to understand. Web-based visualizations enable operators and manager to drill down into the detail at any point.”
Bühler Insights brings it all together
All the data points feed into a central Bühler Insights system, an ISO 27001 certified platform, securely hosted by Bühler Group.
As well as helping customers make smarter decisions, this new capability can also lead to a new level of collaboration. Oudi Zhao, explains: “We live in a world relying on interactions and cooperation and few challenges can be conquered alone. Using these connected services, we can solve problems with remote support and define a proper improvement plan, with our customers.”
In casting, real impact follows pre-emptive manufacturing. For most foundries, steps taken to optimize production processes are often reactive rather than proactive. And this is because capturing data is not enough.
The smart AI algorithms for the foundry industry are based on deep process knowledge of the die casting process to provide solutions that deliver real improvements. These comprehensive, fast to implement, AI in casting driven solutions offer a visual platform for machine monitoring and process optimization. From the performance of individual machines to the comparison of overall output between foundry processes, an AI Platform provide insights to inform decision-making at every level.
The entire production process is to be monitored, controlled, and managed through the AI platforms by analyzing data points of all critical processes in real-time. This enables foundries to recognize quality issues and optimize the production processes for a significant reduction in scrap rate. Other benefits include increasing OEE of casting operations, reducing rejections, and improving environmental sustainability.
While sustainable AI is still in its early years of development, it's becoming crucial to foundries. But an effective and sustainable AI platform can not only eliminate excessive material use and waste, they also make precise recommendations on scrap reduction to help you save energy along your production lines.
Artificial Intelligence is proving to be a game changer by being a catalyst in not only improving the profitability and sustainability of production lines but also providing a considerable and proven reduction in scrap rate between 35% to 75%. More importantly, it’s a step towards zero-waste die-casting.
Using Real-Time Analytics to Make Big 4.0 Gains in Die-Casting
In a hyper-competitive manufacturing world, you need to streamline your production lines everywhere you can. You can gain real-time visibility into your factory floor processes and operations by collecting and analyzing the data produced throughout the die-casting process.
Now available at 0 upfront cost, TVARIT's Sustainable AI powered system for reducing waste in casting means a guaranteed, continual optimization of your plant state. The goal of TVARIT is to bring your plant to its most efficient operating paradigm and improve KPIs across your entire production line.
The FISI – European Foundry Industry Sentiment Indicator – is the earliest available composite indicator providing information on the European foundry industry performance. It is published by CAEF the European Foundry Association every month and is based on survey responses of the European foundry industry. The CAEF members are asked to give their assessment of the current business situation in the foundry sector and their expectations for the next six months.
The BCI – Business Climate Indicator – is an indicator published by the European Commission. The BCI evaluates development conditions of the manufacturing sector in the euro area every month and uses five balances of opinion from industry survey: production trends, order books, export order books, stocks and production expectations.
Please find the chart enclosed or combined with additional information at www.caef.eu
Due to the good mould filling as well as solidification properties, both thin-walled and thick-walled structures can be realised in one component, means the material only has to be used where it is important for the functionality of the component. Together with the good mechanical properties, a considerable lightweight construction potential can thus be realised.
Processing is done in cold-chamber die-casting machines and ensures better casting quality, better mechanical properties such as strength and elongation at break, similar to iron casting or aluminium forgings with gentler operation, as the casting temperature is lower and this benefits the tool.
The high strength and ductility, very good weldability and conductivity of rheocasting components enable efficient lightweight construction in many areas.
Less weight leads to more range and lower energy consumption. Rheocasting can thus contribute to CO2 emission reduction with considerable weight savings.
More efficiency in the production process: Rheocasting can avoid costly reworking of castings.
As examples, Griesebner mentions safety-relevant chassis parts for cars and trucks and some examples of complicated designs in light metal casting that are currently in the test phase.
The equipment required for rheocasting corresponds to the basic equipment for die casting, but it is possible to produce larger parts on smaller machines, because the process can cope with lower piston speeds.
At SAG, casting is done on Bühler Carat, while the starting system for semi-melting is a Meltec system. Here, the globulites are made to grow by electromagnetic stirring and tempering in the crucible.
For the mould used, the rule is: as few sprues as possible, if necessary a thicker sprue is preferred. Otherwise, the usual freedom in die casting applies.
The right time for rheocasting
SAG is the technology leader in rheocasting - this so-called semi-solid process that offers so many advantages.
For example, SAG is the leading manufacturer of rheocasting components, such as safety cabin suspensions for trucks or air reservoirs for the automotive industry. In Lend, € 3.6 million were invested and expanded, because lightweight construction is becoming increasingly important, especially with regard to the electrification of passenger cars.
Electrification, extensive special and safety equipment lead to considerable additional weight of a passenger car, which has to be reduced elsewhere, for example in the chassis, body or drive train.
In order to achieve the CO2 emission limits with combustion engines, lightweight construction is essential.
The demand for the lightweight and particularly robust components is therefore increasing strongly and is moving towards the substitution of forged parts and parts that are welded and have integrated high functionality. The target group for all rheocasting activities at SAG is clear: all OEMs, but also Tier 1 and engineering and R&D.
Stefan Griesebner also talks about completely new projects that are not yet publicly presented; it almost seems that it is the right time for rheocasting.
A platform for presenting the latest technical innovations
For example, the AZTERLAN Metallurgical Research Center presented the development of new tools for process optimization and prediction of component defects based on metal quality and the state of critical process parameters in real time. Casting, he said, is a complex process that involves a large number of parameters with great variability.
Although the automotive sector relies heavily on aluminum and light alloys, the metal that is experiencing the most growth in the automotive industry is steel, he said. With this in mind, an important conclusion of the event was that it is just as important to innovate and drive new developments as it is to recognize which technologies and ideas will last and which ones can be relied upon.
In line with the theme of the conference and the trends shaping the market, the issue of sustainability was an important point in the new developments presented at the Foundry Forum.
Updates from the field of additive manufacturing
The Foundry Forum also offered information on new developments and applications, such as additive manufacturing.
Holger Barth, HA's product manager for additive manufacturing, said, "We are certain that additive manufacturing and 3D printing will have significant market penetration in both the casting process and the post-processing of molten components." In this context, Holger Barth presented the new inorganic, low-emission binder systems for additive manufacturing and 3D printing developed by HA - another important milestone on the way to more sustainable production processes.
At the end of the event, the participants drew a positive conclusion:
The forum is an important platform for industry experts to exchange innovations and new ideas internationally and to jointly develop strategies for the challenges ahead.
David Zorita Leza, General Manager & CEO HA Ilarduya, the main sponsor of the Forum, summarizes a successful event:
Mission Special Stundet/Company's Session "Sustainable Foundrymen's Growth"
TBD | Session Hall
Topic 6 (Student/Company) Sub-sessions
Leader: Hee Soo Kim
Tpoics and Scopes
1. Material ( Ferrous, Non-Ferrous, Composite, New Materials, Mold and Core, etc.)
2. Science (Solidification, Simulation, Direct Observation, etc.)
3. Technology (Continuos Casting, Foundry Technology, Die Castig, Qualtiy Control, etc.)
4. Foundry Issues (Energy & Eviroment, Ecology, Strategy, Education, Safety, etc.)
5. Smart Foundry (3D Printing, AI Foundry, Digitalization, etc.)
6. Student / Company Presentation (Any Subject / Introduction of Company) (Product and Technology, etc.)
* Special Mission Session: Sustainable Foundrymen's Growth
Call for Abstract
We welcome you to contribute to the most up-to-date research and latest developments form around the world.
We will be looking for submissions that highlight new and unqiue scientific methods form the areas of steel technologies.
Step 1 Sign up and log in
Step 2 Download the abstract template and prepare abstract file.
Step 3 Click the [GO TO SUBMIT] button.
Step 4 1. Fill out author info section.
2. Select conference topic.
3. Check your publication plan.
4. Fill out abstract title and upload abstract file.
Step 5 Acknowledgement of your submission will be sent via e-mail.
For more information please visit: www.74wfc.com
