Greensand to Core Shop Reclamation Using Secondary Attrition Greensand back to core-shop What is the objective ? • Greensand foundries have traditionally used new sand for core-shop applications. • As the cost on new sand purchases and disposal increases so the demand to use reclaim sand has increased. • Predominant binders used in core-shop is phenolic urethane cold box. • Technical difficulties associated…

Hydrogen as Engine Fuel Considering the complete fuel cell system, the system efficiency is determined by the number of the integrated components. A part of the energy which is generated by the stack is already consumed within the system (reformer, controller). Even the electric-motor converts only a part of the supplied energy into mechanical energy. The figure shows the comparison of the efficiencies of…

Reviewing alloy additions in the production of safety-critical castings Elkem supported a leading producer of ductile iron high-speed railway tie plates who had experienced challenges to meet the required safety standards, especially with issues around shrinkage control. Increasing safety requirements on rail tie-plates for high speed trains meant that a leading producer had some challenges to meet the…

Strategy Review--Climate change, Corona, Tesla and the consequences The aluminium foundry industry has changed noticeably for everyone since the fourth quarter of 2018. After years of permanent growth (worldwide cast aluminium production 2000 approx. 8 million t → 2017 approx. 18 million t), there was a decline in production figures in the 4th quarter of 2018 for the first time in 50 years (except for the…

Wege zu Energieeinsparung beim Schmelzen und Transportieren von Metall Aluminiumdruckgussverfahren sind bekanntermaßen sehr energieintensiv. Etwa 25 % der Gesamtkosten von Druckgussteilen stehen im Zusammenhang mit dem Energieverbrauch. Ein von StrikoWestofen entwickelter Ratgeber soll Aluminium-Druckgießern dabei helfen, Energie-"Hot Spots" zu identifizieren und zu beseitigen, was einen großen Unterschied…

Ways to save energy when melting and transferring metal Saving energy when it counts Aluminium die-casting operations are notoriously energy intensive. In fact, approximately 25% of the total cost of die cast parts is associated with energy consumption. Guidance developed by StrikoWestofen seeks to help aluminium die casters identify and tackle energy ‘hot spots’, which can make a huge difference to overall…

Outlook Casting Production 2025: How sustainable will the Recovery be? In 2020, the GDP of all major economies recorded a decline. The only exception is China: The Chinese economy recorded a 2.3 percent higher GDP ▪ A strong increase in GDP is expected this year in the USA, due to the vaccination campaign ▪ Within the euro zone, GDP recovery could be weaker in Spain and France in particular ▪ For the German…

Avoiding corrosion on die casting machines Avoiding corrosion on die casting machines through the use of modern mold release agents Corrosion on die casting machines is a major cost driver in HPDC foundries. Corrosion on die casting molds, clamping plates, ejector rods and the machine peripherals result in costs for maintenance, repair, spare parts procurement and production downtimes.

Inoculation of Cast Iron The addition of an inoculant to molten cast iron is advisable and even necessary in most cases, in order to be able to produce castings which fulfill the quality requirements. The mechanical properties and machinability of cast iron with lamellar, compact and nodular graphite greatly depend on the formation of the basic and secondary structure. Both are significantly influenced by…

Semi-Solid Casting of Aluminium from an Industrial Point of View This white paper gives examples of industrialized components and will outline their significant characteristics and advantages in comparison to conventional casting processes. Furthermore the development of Semi-Solid cast components, the production process chain as well as commercial aspects will be outlined. The bottom line is that usually…