Magma optimises autonomous engineering with release of Magmasoft 5.4
With the latest release of Magmasoft 5.4 Magma presents a comprehensive toolbox of new capabilities for the optimisation of casting designs, tooling layouts and robust production processes. By integrating the Magma Approach and the possibilities of autonomous engineering into the software, the user can now fully utilise virtual experiments to ensure sound decision-making and effective root cause analysis.
New white paper discusses high-precision elemental analysis of small parts for aerospace and automotive applications
Spectro Analytical Instruments, a leading manufacturer of advanced instruments for elemental analysis, has published a new white paper entitled: “High-Precision Analysis of Small Parts for Aerospace and Automotive Applications.” Small parts present a challenge for quality control (QC) and production managers of metalworking manufacturers, particularly those in aerospace and automotive applications that demand tight QC at every step of the supply chain.
Materialographic and spectrographic sample preparation – Metkon
Metallography is the science of revealing and evaluating the internal structures of materials. It is one of the most important methods of materials research today, indispensable to the scientist as well as to the engineer. More recently, advanced materials such as high tech metal alloys, ceramics, composites and polymers have appeared which made metallography become an increasingly vital part of modern industry.
Furan resin for 3DP cores and moulds
HA International has recently introduced Enviroset 3D Jet Resin, a low-viscosity thermosetting furan resin that has been specially manufactured for use in all 3D printers for forming sand cores and moulds. It is suitable for use with all types of metal. As noted by the developer, this furan resin contains no nitrogen; is a low-water, non-reportable formaldehyde and phenol formulation. It achieves low viscosity and high-tensile strength in the treated sand.
Morgan Advanced Materials reduces energy waste in foundries with Blue Lightning thermocouple assembly solution
Foundry owners could be wasting money and operating inefficiently by failing to use an accurate and continuous method of measuring the temperature of molten metals in holding furnaces prior to casting. That’s the warning from the Molten Metal Systems business of Morgan Advanced Materials, whose Blue Lightning Thermocouple Sheath delivers a reliable, contamination-free reading within five minutes.
HP presents its new HP Metal Jet 3D printing technology
HP Inc. has just officially presented its new HP Metal Jet 3D printing technology. That’s right. After months of speculation and waiting, the young 3D printing company has announced that it is ready to release its first metal 3D printing system. HP first announced it was developing a metal 3D printing platform almost a year ago. As expected it will be based on MIM powder metallurgy technology.
Grinding Techniques develops new products for high chrome grinding, amongst others, as it announces its acquisition by Tyrolit
Grinding Techniques has adopted the international strategy of strategic business units, and the foundry development unit was born, with dedicated personnel to service and develop this section of industry. This focused strategy has resulted in several significant developments in abrasive products to the benefit of the local foundry industry.
Hardness tester for harsh production environments – Emco-Test DuraVision G5
The Emco-Test DuraVision G5 hardness tester combines a standard load range with a large selection of test methods for the widest variety of applications. Thanks to its sturdy construction, in combination with the simple and swift operation plus precise and repeatable measurement results, the DuraVision G5 hardness tester is also particularly suitable for use in harsh, demanding production environments.
The use of Vega hydraulic cylinders for pressure die casting
Everyone knows the difference between plastic injection moulding and pressure die casting. Although both use moulds to form the final product the moulds are distinctly different, the injection is different, and, more importantly, the materials and temperatures used are not even comparable. That is why, even if in both technologies hydraulic cylinders are used to move parts of the mould, the characteristics required are quite different.
Spectro announces a major upgrade of Spectrotest mobile metal analyser
The Spectrotest mobile spectrometer delivers precise results without compromise when an exact metal analysis is required, materials are difficult to identify, or there is a large number of samples to be tested. Applications include the on-site grade confirmation of incoming materials at the shipping dock or on the production floor, or when metal sorting for value-optimised recycling.
New release agent Ecopart H 17-250 for the most complex geometries
For warm and hot curing organic core and shell moulding processes. Release agents are of immense importance within serial core production, especially regarding complex geometries. The latest offering from ASK Chemicals – Ecopart H 17-250 – was specially developed for warm/hot curing organic core and shell molding processes and excels at reducing scrap and increasing productivity.
Metkon Micracut 202 – a fully programmable automatic precision cut-off machine
The Micracut 202 is a fully programmable precision cut-off machine with colour touch screen control, featuring a high quality Siemens PLC control unit, with automatic table feed cutting system, integrated recirculation cooling unit, versatile clamping options and a wide selection of blades for effortless cutting of a wide range of materials. The machine has a variable spindle speed of between 300 and 4000rpm.
Foseco’s new Feedex K VAK spot feeder
Foseco has announced the product launch of the new spot feeder concept, which is a further development of the company’s Kompressor spot feeder technology. The current advantages, such as minimum footprint area, smallest contact area and optimum moulding sand compaction beneath were adopted from the existing Feedex K concept. From the first idea to the serial stage, extensive tests were carried out.
Remet’s Remasol Jus-Dip – A new colloidal based suspended slurry system
Slurries can be a headache for artists, schools, and small foundries, for many reasons including shell room infrastructure (shell room equipment is a high cost investment), health and safety risks (there are many risks involved in the investment casting process), stock management (five to 10 different materials are required for a traditional slurry) and hard to use (slurries are often difficult to keep in their optimum state over a period of time).
Lauds Foundry Equipment mixer technology
“In recent months Lauds Foundry Equipment has been coming up with innovative ideas and exploring our ability to manufacture products that we believe are equal to and in most cases, better than others in the industry. How do we do this you may ask? From a well developed base range of products, many years of research into how others around the globe do it, through tradeshows, client visits and feedback from our partners in the market,” said Kevin van Niekerk.
Scrap metal recycling sorting with the Bruker S1 Titan Series XRF
The recycling of scrap metal is an important global industry economically and environmentally. Scrap metal recycling reduces metals in the general waste stream, maximises the use of mined metals, and generally contributes to a healthy economy. Recycling scrap metal requires careful sorting of metal alloys by type. Since a typical scrap yard or scrap metal processing facility can receive any type of metal at all, it must have tools to be able to correctly sort the metal, and to verify grade or composition after processing.
Disa’s entry-level Disamatic C3 high-pressure moulding machine is now available globally
The first Disamatic C3 line was commissioned in China in August 2016 and in 2017 alone, 22 Disamatic C3 lines were installed across Asian markets. With nine new orders already signed, including one in Ukraine, Disa has decided to launch the Disamatic C3 globally, in three speed versions: C3-150, C3-250 and C3-350.
Bruker Q4 Mobile spark spectrometer
Q4 Mobile is one of the most compact and lightest integrated spectrometers. Even battery may already be built-in (option) and the 24 kg unit can run independent from mains supply. The ultra-light probe, the light hybrid cable makes this configuration very handy. For special tasks, various cable lengths are available.
High casting quality and short cycle times – Hüttenes Albertus Chemische Werke
Eco Lube 108, an ultra-modern, wax-free release agent, offers outstanding re-lease performance and is particularly suitable for large-area castings such as automotive parts and electronics housings. The wax-free formulation keeps the mould frame clean, extending cleaning intervals and improving process reliability.
Hitachi High-Tech Analytical Science launches Foundry-Master Pro2
Seamless quality control is essential throughout the metals industry, from trace element analysis in scrap metal, to incoming materials inspection, melt process control and goods issue. The Foundry-Master Pro2 optical emission spectrometer is a metals analyser engineered to deliver superior analysis at every stage, without compromising your productivity.
The right filters – Drache
Since the company’s founding by Frank Drache in 1984, Drache GmbH has been manufacturing a wide range of innovative products and equipment for foundry technology. For foundries doing steel, super-alloy or iron castings, either for large components or small to mid-size pieces, Drache believe they have the right ceramic foam filters to achieve optimum results.
Morgan Advanced Materials insulating firebricks maximise energy savings
Industrial kilns and furnaces rely on high temperature insulation materials to optimise production yield and reduce energy costs, which can increase rapidly if excessive heat escapes from the operation point. Due to their inherent low heat conductivity and other benefits derived from structural strength and ease of placement, insulating castable refractory materials are key for this energy-saving process.
Foundry modernisation with GOM optical 3D metrology solutions
GOM systems allow for inspection planning based on design data. In pattern and mould making, the targeted correction of tools and models and the inspection of fitting of mould halves, cores and sliders are possible. During try-out, cast parts are checked for shape and dimension: part geometry, material thickness, shrinkage and warpage.
Dynamic dosing system automates ductile iron treatment – Elkem
Elkem, a leading supplier of alloys to the iron foundry industry and their equipment partner Euromac, a source for foundry automation equipment, have joined forces to develop and manufacture a dynamic dosing system. The dynamic dosing system enables foundries to precisely and automatically calculate, dose and position the treatment alloys into a dedicated pocket in the treatment ladle for high quality ductile iron production.
New Ecocure Silver for reduced emissions
The new cold box binder Ecocure Silver from ASK Chemicals reduces emissions during aluminium permanent mould casting and offers technical advantages when compared to conventional cold box binders. With the development of Ecocure Silver, the ASK Chemicals team has succeeded in producing a solution for aluminium casting that builds on the Ecocure Blue technology platform.
Lighter, lower-profile carriers result in better heat treating
Foundries that install heat-treating capability may not realise all the factors contributing to the efficiency and productivity of that process. StrikoWestofen, a furnace builder more recognisable for melting and holding systems, reported it took “a holistic, process-oriented heat treatment approach in which the interplay of furnace system, quenching unit, and product carrier is fine-tuned.”
S1 Titan PMI Analyser
The S1 Titan is among the lightest (1.5 kilograms, including battery) tube-based handheld XRF analysers on the market today. Fast analysis speed and exceptional accuracy are two key attributes that help define the S1 Titan. Other innovative features include an integrated touch-screen color display, 50 kV X-ray tube, SMART GradeTM timing, SharpBeamTM optimised X-ray geometry, Silicon Drift Detector (SDD).
Foseco launches new, insulating lining system
Foseco has developed a new, insulating lining system for use in dosing and low-pressure furnaces in aluminium foundries. The system, based on Foseco’s Insural range of non-wetting and insulating refractories offers numerous benefits to the foundryman. The adoption of energy efficient furnaces in aluminium foundries is widely regarded as best-in-class.
Spectro introduces Spectro Midex MID05 small-spot ED-XRF spectrometer for precious metals testin
Spectro Analytical Instruments has introduced the Spectro Midex MID05 spectrometer – a fifth-generation, fast, accurate, small-spot energy-dispersive X-ray fluorescence (ED-XRF) analyser for precious metal testing. The new, compact Spectro Midex MID05 spectrometer delivers improved sensitivity and speed, and represents a smart alternative to fire assay testing.
Elkem’s Topseed conditioner helps to improve nodularisation
A vast amount of literature and advice is written on the best ways to nodularise ductile iron with magnesium ferrosilicon ladle design, pockets, alloy compositions and so on. However, little is said about the Mg alloy reactivity management to get the best magnesium recovery. Elkem has developed a family of specialised materials designed to optimise the magnesium recovery and reduce reactivity.
Struers introduces high-capacity Rockwell and entry level Vickers hardness testers
Struers has introduced a completely new generation of hardness testing equipment for materialographic quality control in both laboratories and on production floors. The new series of nine Duramin products offer a cost-efficient quality-control process to the market. The products were launched earlier this in Stuttgart at the Control 2017 exhibition.
Industrial filtration solution system for the future – Nederman MikroPul FS Flat bag filter with reverse air cleaning
For more than 70 years the Nederman Group has been one of the world’s leading suppliers of products and solutions within the environmental technology sector, focusing on industrial air filtration and recycling. Nederman products and solutions contribute to reducing the environmental impact from industrial production processes and to creating a safe and clean working environment whilst boosting production efficiency.
MTS Criterion range of tensile testing equipment carefully engineered and seamlessly integrated
The MTS Criterion range of tensile testing equipment offers a comprehensive family of load frames, which performs accurate, repeatable monotonic testing on everything from thin-film plastics to high-strength structural steel. These high-stiffness frames are designed for years of high-speed, low-vibration performance across a broad range of force capacities.
New Omega catalogue available
UK based Omega Foundry Machinery Ltd, a company that has over 30 years experience in the foundry machinery sector, has released its latest catalogue that features advanced equipment solutions for the metal casting industry. The catalogue is printed and designed in an easy to navigate format that includes the essential information on each individual product that the company manufactures. Full colour pictures of these products are also included.
SI Group ǀ HA – War on fines
Whilst no two foundries are the same and all have different sand systems and requirements, there are many variations of sand reclamation plants available. Modern sand reclamation plants have evolved in such a way that even the smallest foundry can be accommodated in terms of floor space required by the plant and also in terms of investment and running costs.
Virtual commissioning in the “digital factory” shortens the commissioning phase and speeds up the ramp-up – Küttner Automation
“Virtual commissioning” provides the possibility of testing and verifying the perfect functioning of automation systems and optimising controls and process steps before the “real” commissioning takes place in the foundry. Various successfully accomplished projects at the Gienanth iron foundry in Eisenberg, Germany, have demonstrated that commissioning times can be markedly reduced.
Endress+Hauser’s E-direct online store
Endress+Hauser’s E-direct is an online store that allows customers to easily and securely order measurement devices, including pressure transducers and switches, temperature switches and thermometers, paperless recorders, digital displays, level switches and flowmeters, as well as pH, conductivity, oxygen analytical transmitters or simply get an overview of all the entry-level products and more. Instruments are available for purchase around the clock.
Morgan Advanced Materials develops new materials for use in aerospace components
Following extensive research and development, Morgan Advanced Materials has successfully produced two new materials which offer superior performance and higher casting yields when used in injection-moulded ceramic cores for the aerospace market.
Struers AbraPlan-30 – A reliable, high-capacity machine for fast and efficient plane grinding
The Struers AbraPlan-30 brings a wide array of features and benefits, enabling users to optimise their grinding process to save time and consumables. The robust plane grinding machine available on the materialographic market, AbraPlan-30 is a powerful and fast plane grinding machine ideal for laboratories or workplaces carrying out testing of very large specimens.
Risers for maximum yield with minimum volume – ASK Chemicals
Frequently, fiber sleeves are used in steel casting applications. These conventional sleeves contain, in addition to the fibers, rice husks that may lead to casting defects. Moreover, these slurry sleeves do not utilise their full volume for counteracting shrinkage defects, with the result that the effective yield is only 30%.
Morgan Advanced Materials enhances crucible performance with internal coatings for aluminium casting applications
As aluminium becomes the material of choice for automotive manufacturing, a global leader in advanced material development and application is helping aluminium casters to improve quality of output and reduce rejections by avoiding metal contamination in the melting and holding process.
Struers’ StructureExpert – The new way to achieve fast and reliable micro structure verification
StructureExpert challenges conventional structure verification technology with time-saving automated functions. Designed for both the production and lab environments, StructureExpert is an all-in-one solution dedicated to your particular application. Challenging conventional technology, StructureExpert does away with conventional and time consuming positioning and adjustments.
Innovation in investment casting – Remet
Remet prides itself on being a technology led company that continually strives to push the boundaries of the materials that they offer. Remet’s expanding product range offers the caster a wide range of choice when choosing the most appropriate materials for their process. This includes casting waxes, ceramic shell binders and refractory materials and precision investment casting support products.
Spectro introduces new Spectroport portable arc/spark OES metals analyser
Spectroport delivers many advantages of Spectro’s flagship mobile Spectrotest OES analyser in a smaller, lighter unit featuring effortless point-and-shoot performance for fast, ready response, flexible portability, intuitive ease of use and minimal standardisation efforts.
Pangborn Group – all around the industries
In today’s modern production technology you will find many processes, solutions and options to handle different work pieces in surface technology. The miscellaneous industrial applications in this special technology sector deal with the surface of solid matter.
Installation of dosing furnaces with Insural*
“The solution for a dosing furnace is completely dry installation with Insural*. Precast shapes and high insulating backing materials offer huge energy savings, no sintering, low density index of the melt immediately and easy cleaning,” says Arndt Fröscher, Foseco Europe and Jens Ohm, Foseco Germany.
Oxford Instruments launches Vulcan handheld metals analyser
Oxford Instruments has launched Vulcan, the fastest metals analyser with the most advanced reporting tools on the market, the company says. Vulcan is an ergonomic, balanced handheld LIBS (Laser Induced Breakdown Spectroscopy) analyser with a simple user interface.
Hardness testing reinvented with the Internet of Things
Proceq has introduced its Equotip® Live IoT-based hardness tester that leverages smartphone and wireless technology to access data stored in the Cloud. The new generation wireless impact device and mobile app – Equotip® Live – with real-time data sharing and cloud backup creates a new industry standard in portable hardness testing.
Future of casting
Casting and forging measuring can be laborious and time consuming in the field unless new technologies are embraced and used. Optical measuring systems are at the forefront of new technologies in the industry and can save time and effort, while returning accurate information.
ASK Chemicals successfully rolls out new release agent for inorganic processes
The newly developed release agent Ecopart H-INO 50, which is suitable for all inorganic core and mould-making processes such as the Inotec system, impresses due to its application properties while at the same time being free from any harmful constituents and solvents.
Simulation evolves to optimisation – MAGMAsoft
As opposed to real-world trials autonomous optimisation using simulation tools provides significant advantages in the thoroughness of the search for solutions and in the speed of the search. It can also handle many interconnected variables at the same time and automatically rank their influence on the outcomes.
ABB introduces IRB 1200 Foundry Plus 2, smallest foundry robot in its class
ABB Robotics has unveiled its latest foundry robot for material handling and machine tending, the IRB 1200 Foundry Plus 2. The smallest foundry robot in its class, this compact robot can increase flexibility and reduce cycle times for precision die casting processes such as smart phone cases and other electrical components.
Altair reveal new design processes and software tools for additive manufacturing
At this year’s formnext 2016 in Frankfurt, Germany Altair presented the latest versions of its simulation software suite HyperWorks® 14.0, concept design and optimisation tools solidThinking Evolve® as well as Inspire® 2016, highlighting new design processes for the development and manufacturing of innovative products.
Tracer 5i handheld XRF spectrometer
Bruker introduces the next generation Tracer handheld XRF spectrometer ideal for methods development, research and complex materials. The new Tracer 5i is reconfigured to be more powerful, flexible and fully field interactive, while retaining the unique features and comprehensive analytical software that the Tracer is recognised for.
Kerphalite™ KF for special applications in the foundry industry – Hüttenes-Albertus
Complex cast parts such as turbocharger housings play a central role in the design of modern high-performance engines. Due to its particular characteristics silica sand has its limits as a moulding material when it comes to casting finely structured components, reduced wall thicknesses and perfect surfaces.
Emerging technologies and design for manufacturing – The metal casting process – Click2Cast
Product design is rapidly changing to keep pace with the requirements of new product development with increasingly short design cycles and high performance requirements. In the recent IKB Deutsche Industrial Bank report on manufacturing, some of the top trends reported are listed in the article.
InspecVision Opti-Scan system – A castings inspection solution
Most manufacturers are familiar with contact CMMs, and their lack of speed and the time and skill it takes to programme the machines. However, they are only now becoming familiar with the limitations of other noncontact 3D scanning systems such as laser scanners or white light measuring scanners.
Spectrocheck stationary metal analyser
The Spectrocheck stationary metal analyser is a high-quality, compact, affordable instrument, which is ideal for routine analysis of elemental content in iron, aluminium and copper-based metals. The Spectrocheck stationary metal analyser is specifically designed to meet the performance requirements and the budgets of small and medium-size foundries and machining operations.
Updated controls for improved finishing technology – Vulcan Engineering
Vulcan Engineering has recently made several updates to its Foxall® product with a new system controls and an operator interface that is more user friendly than ever, they say. This system has always offered simple programming (online or offline), but now software updates make it more efficient and easier to use.
MTS Acumen Electrodynamic test systems
MTS Acumen electrodynamic test systems deliver the capabilities researchers and test engineers need to perform high-fidelity dynamic and static tests that are vital to improving the efficiency, reliability and performance of materials and components. At its core is energy-efficient electrodynamic actuation.
Water jacket bridge cores made of resin-coated sand
Powerful and lightweight, delivering high performance with minimal fuel consumption: these are the requirements for modern engines. Implementing high standards begins with an ever more complex and filigree casting: the crankcase. Being able to cleanly and faultlessly cast the water jacket poses a great challenge for foundries.
New coatings will help limit contamination in crucibles
Contamination of molten metals by crucible materials during melting operations can be minimised by coating the interior surface of the crucible, helping to prevent reactions between the metal and the crucible while acting as a diffusion barrier to reduce impurities.
Increased yield and productivity with Exactcast mini-riser technology – ASK Chemicals
Frequently, fiber sleeves are used in steel casting applications. These conventional sleeves contain, in addition to the fibers, rice husks that may lead to casting defects. Moreover, these slurry sleeves do not utilise their full volume for counteracting shrinkage defects with the result that the effective yield is only 30%.
The new Hawkeye® V2 video borescopes
Manufacturers of complex castings now have the Hawkeye® V2 video borescopes, the next generation of fully portable, articulating, video borescopes manufactured by Gradient Lens Corporation, to inspect their castings. “We know portability, image quality, and cost-efficiency are the most important factors for inspection and maintenance teams,” said Dr. Doug Kindred, Gradient Lens’ President and Chief Scientist.
Innovative solutions for thermogravimetric analysis
Since 1987 companies around the globe have trusted IMP to provide them with innovative, quality laboratory equipment and instrumentation. Thermogravimetric analysis or thermal gravimetric analysis (TGA) is a method of thermal analysis in which changes in physical and chemical properties of materials are measured as a function of increasing temperature (with constant heating rate), or as a function of time (with constant temperature and/or constant mass loss).
SolidWorks aids CNC machine to slash lead times on patterns
Following the installation of a CNC pattern making system, a UK foundry has slashed the lead time for high temperature castings from a maximum 18 weeks to as little as two weeks. The increase in the speed that bespoke new casting designs can be produced has also reduced the initial cost, making smaller batches of castings more economic and reducing the cash tied up in stock.
New Spectro xSort handheld XRF analyser delivers improved speed, precision in analysis of light elements
The design, performance, and simple operation of the Spectro xSort handheld spectrometer make it ideal for performing positive material identification (PMI) for infrastructure integrity testing at refineries, power plants, and petrochemical complexes, as well as scrap metal analysis and sorting in the recycling industry.
The challenge of cooling castings without 120 metres of conveyors
Does your foundry have the available space needed to cool finished castings effectively using conveyors? How about the proper ventilation for such an installation? Are there elevation restrictions? General Kinematics has a process available to handle the problem, and a single machine that will address the design dilemma.
Proceq launch Equotip 550® UCI – a UCI probe with adjustable test load
One of the world leaders in portable measurement solutions for non-destructive testing, Proceq, has announced the first in a series of upcoming product launches with the introduction of the new Equotip® UCI, an ultrasonic contact impedance hardness testing probe with adjustable test load.
Oxford Instruments launches Foundry-Master Optimum, a high performance compact benchtop metals analyser
Oxford Instruments has launched a new high performance benchtop metals analyser for the metal production industry. The Foundry-Master Optimum has been designed to meet the demands of seamless quality control required by the industry and offers an excellent price-performance ratio.
New Morgan stopper rods for ferrous applications
This latest innovation from Morgan’s Molten Metal Systems business, designed specifically for auto-pour applications such as unheated tundish systems as well as press pour systems, is based on alumina-graphite compositions which are primarily for grey and ductile iron applications.
Increased safety measures in cut-off technology
The Fox® Air Float Cut-Off machine is ideal for gate and riser removal on small to medium size castings, or castings on runner bars or trees. It is well suited for processing castings that are too heavy for operators to handle, as the air float feature makes moving large weights almost effortless.
General Kinematics Vibra-Drum®
General Kinematics’ Vibra-Drum® sand and casting equipment has revolutionised high volume mould and sand handling for foundry applications, says the company. Proven in hundreds of applications around the world, this versatile two-mass system provides a shakeout system which prevents damage to castings, reduces sand lumps to grain size, and equalises shakeout sand and casting temperatures.
ASK Chemicals expands its product portfolio
Askroning pre-coated moulding sand for the shell moulding process is especially suitable for the production of filigree components in all commonly available casting alloys. The pre-coated sands from ASK Chemicals have the advantage of high dimensional accuracy, with good hot and cold bending strengths and good disintegration and decoring abilities.
Prevent the wrong alloy from causing environmental disaster
Optical emission spectrometers can contribute decisively to prevent accidents. Bruker Elemental’s Q4 Mobile provides the petrochemical and metals industries with a compact metal analyser, capable of analysing the critical carbon content in used steel. The smallest concentrations of carbon in the ppm range impact the steel’s durability, strength and weldability.
Exactcast technology even more efficient
ASK Chemicals has significantly improved its Exactcast riser technology within the last few years. Recent developments such as Exactcast Optima mini-risers provide important benefits to foundries. With the integration of riser data into the new MAGMA5 version, foundrymen have access to comprehensive validated data of the Exactcast riser when designing the riser or gating system.
The Q8 Magellan spectrometer – Bruker’s flagship for metal analysis
To describe Bruker Elemental’s relationship with its customers, Andreas Kunz, Managing Director of Bruker Elemental, needs a single word: “customise”. Where others come along with standard products and standard service, Bruker offers customer-oriented solutions that exactly fit custom needs.
SI Group South Africa launches new hybrid furan resin system
SI Group South Africa have partnered with their global partners HA (Hüttenes-Albertus) to improve environmental conditions and working conditions within the foundries to initiate a strong drive to reduce emissions. HA’s new furan resin systems have been developed and are being applied in foundries globally. Locally SI Group HA is currently in the process of launching the recently developed resins systems.
Efficient quality control: 3D inspection of gear transmission casings with Aicon scanners
ZF Friedrichshafen AG is a leading worldwide manufacturer of gear transmissions, and developer and producer of technologies for drive-line and chassis technology. The complex gear transmission casings for commercial vehicles are made of aluminium using the method of pressure die-casting.
Increasing plant availability with expanded Warman® WBH® slurry pump range
Plant availability is paramount in all commodity sectors and there is an increasing emphasis on optimisation of pumping systems from end users as part of their cost savings drive. “One of the options in terms of reducing operating cost is to replace older technology with new,” says Rui Gomes, product manager slurry pumps for Weir Minerals Africa and Middle East.
Oxford Instruments continues to develop metal alloy sorters – mPulse, the handheld laser induced breakdown spectroscopy (LIBS) metals analyser is now available
Oxford Instruments has introduced a new model to its range of metal alloy sorters. mPulse, the handheld laser induced breakdown spectroscopy (LIBS) metals analyser is now available as two options.
New standards set for mould cleaning using Asco technology
In cooperation with Hüttenes-Albertus, a leading manufacturer of chemical products, Asco Carbon Dioxide’s dry ice blasting technology is setting new standards for the removal of coatings on moulds. Mould and tool cleaning has great importance in foundry operations.
Combicore cores for lightweight construction in die casting and other casting processes
Highly stable cores used by foundries to implement oil and cooling channels in castings. For the first time, this method enables undercuts even in high-pressure die casting. New technologies and lightweight construction require new cooling concepts.
New Struers LaboSystem manual/semi-automatic polishing machines
Designed for reliability and speed for manual and semi-automatic grinding and polishing in the lab or next to the production line, the LaboSystem is ready for your inspection. A choice between seven robust combinations gives you adaptability for your changing needs in demanding production environments.
StrikoWestofen’s closed transport system for aluminium melt protects employees and equipment
Safety for people and equipment: this is a hot topic, especially in aluminium foundries where liquid metal is handled. With the new Schnorkle, liquid aluminium is transported from the melting furnace to the melting or holding furnaces in a closed container, and introduced there using a transfer pipe without the need for tipping.
New White Paper from Spectro: Why overcoming matrix effects with XRF analysis is critical for high-accuracy results
A new white paper explains why overcoming matrix effects associated with X-ray fluorescence (XRF) analysis is critical to achieving consistent high-accuracy results. The paper, titled “Mitigating Matrix Effects with Advanced Spectra-Handling Functionality When Using XRF for High-Accuracy Elemental Analysis,” is available to download.
Filtration technology for iron and steel foundries – Foseco
Since the introduction of Sedex iron filters more than 25 years ago, there have been many advances in terms of product performance and application technology. Today iron filtration is regarded by most foundries as standard practice – the value and benefits of effective ceramic foam filtration are well documented and understood.
IMF Group launches three new machines
At the recent GIFA 2015 the IMF Group took the opportunity to launch three new machines. Amongst these, IMF launched one machine each in the field of moulding, core-shooting and shot-blasting applications in the foundry industry respectively.
Focus on communication – New data manager
The device, with its new enhanced features, is a step from a data manager to a centralised monitoring and maintenance system for small solutions. The update of the Advanced Data Manager Memograph M platform completes the Endress+Hauser portfolio update.
Through thick and thin – the melting furnace for structural components
This melting system is designed to function extremely energy-efficiently, even with exceedingly thin-walled returns. Thanks to its special shaft design, the BigStruc can even handle returns with an area of up to 2.5 m2 without any problems whatsoever.
Automated transport and cooling system for castings from Magaldi
The Magaldi Casting Cooler (MCC®) is an automated system for transporting and cooling castings from moulding lines. It may also be used as a workstation for de-gating operations, avoiding further need for a conveyor. Magaldi hot bulk-material handling systems are installed in power plants, cement manufacturing, and mining and metallurgical operations.
Bruker Elemental’s Q2 ION optical emission spectrometer
Bruker Elemental’s Q2 ION optical emission spectrometer (OES) has been extremely successful for several years in Asia. Bruker took one of its high-end instruments, slimmed it down and presented a powerful, ultra-compact device for PMI, sorting and metals analysis. It caught on quickly and is still a fast seller.
Simulation as the new platform for real progress in casting technology
Metalcasters that subscribe to simulation software don’t have to wait for a major event to feel the thrill of a new technical development or process breakthrough: over the past decade or so, the expanding scope of process analysis and simulation has meant that every production cycle offers the potential for new discovery.
Hard-faced thermowell for erosive environment
When working in the metal industry, we constantly deal with extremely harsh and erosive environments. This causes damage to instruments, more often temperature probes. Endress+Hauser South Africa decided to take this challenge and develop a solution to improve the thermowell, which ensures that the instruments last up to 10 times longer than usual.
Geopol reclaimable inorganic binder
The ever growing environmental issues of fumes, odour and waste disposal have focused increased attention on the need to develop a process to reduce the environmental impact of casting production. The Geopol inorganic binder system, designed to produce moulds and cores, is a sand binder, cured by adding a liquid hardener. The Geopol system is an ester cured, alumino-silicate geo-polymer.
PMI Master SMART- a true portable OES
Oxford Instruments’ portable arc / spark metal analyser, the PMI-Master Smart is a true portable and full range optical emission spectrometer designed for metal analysis especially in hard to reach places. Despite its 15kg light weight and compact dimensions, the PMI-Master Smart offers full analysis functions and high performance.
Foseco innovations at GIFA 2015
June 2015 saw Foseco have its biggest ever stand at the GIFA exhibition held in Düsseldorf, Germany. With a total floor space of 1200 m², the stand was divided into three zones featuring the latest advances in foundry process technologies for iron, steel and aluminium foundries.
Avoiding disasters in piping systems subject to sulfidic corrosion
Carbon steel piping with silicon content less than 0.1% has been shown to have accelerated corrosion rates when exposed to hydrogen-free conditions where sulfur compounds are present at elevated temperatures (>450 degrees C). Accelerated corrosion related failures can easily result in major accidents that cause worker injury or unplanned outages.
ASK Chemicals launches Ecocure™ Blue technology
Foundries are constantly seeking not only to reduce emissions in the foundry process but also to optimize their added value. An important point of leverage to reduce emissions while maintaining or increasing performance is the cold box binder system. The new Ecocure™ Blue technology from ASK Chemicals gives the foundry important environmental benefits while providing excellent performance.
Robust and reliable steam measurement with Prowirl 200 vortex series flowmeters
Flow measurement based on the vortex principle is well known for its robustness and reliability – it’s a tried and tested technology for liquid and gas flow measurement. However, the new Prowirl 200 vortex flowmeters go one better and can even detect moisture levels in steam!
Endress + Hauser launch universal training rig
Endress + Hauser have launched a R1.8 million Universal Training Rig (UTR) that will allow trainees to experience “real life” instrument and control operation. Purpose built for Endress + Hauser South Africa at the company’s Application Training Centre in Reinach Switzerland, the UTR utilises 20 devices from the company’s extensive range of flow, level, pressure and pH measuring instruments in a variety of flow and control loop configurations.
Proceq introduces the Equotip 550 – the most versatile all-in-one solution for portable hardness testing
The new Equotip 550 is an all-in-one solution combining the Leeb and Portable Rockwell methods and will be directly compatible with upcoming developments. The new generation Touchscreen Unit leverages the high measuring accuracy with an unmatched user experience leading to increased measurement efficiency.
Quality assurance made easy – Endress+Hauser
The ability to see the chronological history of a remote station at any time is one of the advantages of the new Ecograph T RSG35 with its redesigned web server. The device sets a benchmark in the category for data recording and quality assurance. With its input configuration of 4/8/12 universal input’s the Ecograph T offers the possibility of replacing two recorders at a time. Alternatively, the screen recorder is also available with MODBUS RTU/TCP Slave.
New Spectro xSORT handheld EDXRF spectrometers deliver reliable on-site identification, elemental analysis and screening
Each of the three versions of the Spectro xSORT energy dispersive X-ray fluorescence spectrometers delivers repeatable, laboratory-quality results in a matter of seconds and is optimized for fatigue-free on-site measurements. Moreover, the proven field-ready design features simple user-friendly displays and efficient ergonomics to make the devices extremely easy to use.
Newly developed ASK Chemicals’ Veino Ultra 4618 hybrid additive
The use of additives makes it possible for expensive speciality sands to be replaced to some extent, thereby saving on material costs. Global player ASK Chemicals has developed a new hybrid additive for use in cold box and Pep Set™ applications and rapidly implemented a successful transition to series production. The new additive, Veino Ultra 4618, combines the strengths of organic and inorganic additive technologies and offers a high level of process reliability in series casting.
Equotip portable dynamic hardness testing
It is either not cost effective or not even possible at all to perform the hardness test on larger metal work pieces such as cast or forged parts or thick plates with the traditional, static methods. The portable metal hardness testers developed by Proceq in the last 30 years are a suitable alternative: In the 1970s Proceq released the famous portable Equotip testers that are now available in its third generation, paving the way for the metal hardness testers Equotip Bambino 2 and Piccolo 2.
Reliable temperature measurement with new thermowell materials
When it comes to manufacturing and finishing metal, heat plays a significant role. However, a specific degree of heat rather than intense amounts of heat is a critical factor. This is because the actual temperatures in the individual production processes are of vital importance to the end product. If the specified temperature is not reached and maintained, this can be detrimental to the quality of the product.
Remarkable casting advantages of the new Inotec™ generation
ASK Chemicals has succeeded in further enhancing its inorganic Inotec™ technology through its new Inotec™ TC 5000 and Inotec™ HS 3000 products. The new developments lead in particular to improved shakeout and higher moisture stability of the cores. The mounting advantages of using Inotec™ technology for the foundry industry are not only odourless core production and odour-reduced casting, but also the significantly lower cleaning required for machines and tools.
New handheld thermometers for molten metal
The stand alone Cyclops Meltmaster, manufactured by Land Infrared, is a hand held non-contact industrial thermometer that has been specially designed for foundry applications, and has the ability to withstand harsh foundry conditions while taking accurate measurements of molten metals of up to 2000°C.
The new Struers Lavamin fully automatic cleaning unit
Gone are the days of standing at the sink cleaning specimens with soap, flushing them with alcohol and drying them! Lavamin uses a patent-pending and entirely automated process with a combination of ultrasound and water rinsing, together with high-speed spin-drying of the specimen holder/mover plate. You can save up to 20% of your total preparation time with a faster, automated cleaning process.
Pyrometry sheaths for use in furnaces
Morgan Molten Metal Systems recently announced the release of its HotRod pyrometry sheaths and other pyrometer assembly products, which are made of an erosion-resistant clay-graphite mix with special plasticity properties and protect thermocouples in furnace heating control systems.
High-stability ceramic core material
Morgan Advanced Materials has introduced P-59 ceramic, a high-silica core-type material with a fine particle size distribution. The P-59 material is a further development of the previous P-52, and according to Morgan it represents “a breakthrough into the high-stability realm of materials.”
Aluminium-oxide cutting wheels for cutting steel, ferrous metals
Norton | Saint-Gobain has introduced an upgrade to its Norton Gemini RightCut Wheels, providing the best aluminium oxide (A/O) option for cutting steel and ferrous metals. The latest generation Norton Gemini RightCut wheels are 100% A/O abrasive, infused with a new bond technology and process, for a thinner wheel design and low kerf loss.
Blockage detected – danger averted!
More than a third of copper production at Aurubis, the world’s largest recycler of copper, is achieved as a result of processing debris containing copper and precious metal such as dross, slag and dust as well as PCBs, electronic scrap, used catalytic converters and materials from the waste industry.
Bruker Q2 ION metal analyser now also available for zinc
Bruker Elemental GmbH has the Q2 ION now extended by a further NE application. It is now available to use on Zamak alloys for die-cast zinc such as ZL0400, ZL0410, and ZL0430 which can be analysed. But also the composition of electroplating zinc and many other alloys of zinc base can be quickly, accurately and reliably determined with Q2 ION.
Norton SA launches latest generation Foundry X medium diameter cut-off wheels for the foundry market
Saint-Gobain Abrasives has introduced the latest generation of medium diameter cut-off wheels for foundry environments, under the Norton brand. Developed with the new Foundry X bond technology, the cut-off wheels are engineered to increase cut rate and wheel life in all foundry cut-off applications.
Morgan Advanced Materials: Silicon carbide degassing rotors offer long life and enhanced performance
Morgan Advanced Materials has announced the launch of its new generation of degassing rotors for secondary aluminium processing applications. Building on its extensive experience of materials science and metal casting products, Morgan has produced the first one-piece degassing rotor in silicon carbide, delivering a cost-effective and high-performance alternative to the graphite material traditionally used for this task.
StrikoMelter: New hot gas baffle
A shortened melting-free process, reduced gas consumption and an improved material yield: to increase still more the efficiency of your StrikoMelter melting furnaces, the StrikoWestofen Group (Gummersbach) has now developed a heat-resistant shaft cover. This so-called “hot gas baffle” reduces the duration of the melting-free process during furnace cleaning by approximately 20 minutes each time says StrikoWestofen.
Residue-free castings with Miratec TS from ASK Chemicals
As a partner to the automobile industry, foundries are under the pressure of ever increasing demands. An important component in the competitive environment is the casting of engine blocks with a minimum amount of coating residue. Coating residues in the cavities of the engines tend to clog the filters prematurely and endanger quality standards. For this reason, and to lengthen the service life of an engine, coating residue is limited to 300 mg per engine block.
On-line Shop streamlines purchasing, maintenance and spare part management
Production is often seven days a week, 365 days a year, so intelligent spare part management is indispensable to guarantee maximum availability of the facility. An important part of this spare part management is the fast restocking of spare devices, spare parts and consumables. With Endress+Hauser’s Online Shop, one can streamlines the process for replacing or sourcing new measuring instruments.
Advanced material preparation systems – Struers Tegramin
The new Tegramin preparation system offers innovative solutions to improve your preparation results and help you deal with a variety of specimens and materials. The sturdy and rigid design ensures high quality preparation results and reliable day-to-day operation. Reproducibility is ensured by automated process control yet it is remarkably easy to operate.
Ecocuretm Solventless cold-box technology now also available for iron casting applications
ASK Chemicals has now successfully transferred the established Ecocuretm Solventless (SL) technology to iron casting applications. With this new cold-box technology from ASK Chemicals, foundries can not only dramatically reduce emissions, but also improve performance.
Selee IC™ aluminosilicate-based ceramic foam filters
Since Selee introduced the first silicon carbide based ceramic foam filter in the late 1980s, the product line has grown substantially and the company has delivered hundreds of millions of these filters into a variety of casting applications. This filter has gone through some improvements over the years, and Selee’s latest silicon carbide offering has been the “Selee IB” formulation introduced in 2002.
LPGmas – The new Coriolis flow meter for LPG with volume correction function
Liquefied Petroleum Gas (LPG), a gas mixture consisting primarily of propane (C3H8) and butane (C4H10) – both saturated, chain-type hydrocarbon compounds – normally occurs as liquid natural gas when crude oil is being pumped from significant depths, or is obtained as a by-product in the crude oil refining process.
Norton X-Treme flap grinding discs
The X-Treme R828 is a unique high performance flap grinding disc from Norton, offering a higher and faster metal removal rate than standard products. Designed to work on both carbon steel and stainless steel, the X-Treme R828 discs can provide a 20% increase in cut rate and 30% increase in product life, according to Norton.
Expand your cutting capabilities with Discotom-100/-10
Discotom-100/-10 are versatile table top cut-off machines designed to give you a cost-efficient way to expand your cutting capabilities and streamline your cutting processes. Spacious, versatile and easy-to-use, Discotom-100/-10 deliver exceptional cutting flexibility and more cutting options so you can clamp and cut all types of workpieces efficiently, with less effort and minimum deformation.
RadEye PRD radiation meters for use in the recycling and scrap markets
Radioactive sources can find their way into scrap and recycling yards through both naturally occurring radioactive sources, such as scale on pipes in the oil and gas industry and through orphaned industrial sources. Turning away a load could jeopardise a supplier relationship that has been built through extensive efforts.
New fire-resistant interchange parts shorten relining of Westomat dosing furnaces
A new on-site relining concept for Westomat dosing furnaces, in cooperation with a leading refractory supplier, the StrikoWestofen Group has now developed refractory interchange parts. These prefabricated furnace parts are delivered completely dried and sintered.
Improving crucible installation
Morgan Molten Metal Systems is proud to now offer CBS Black Powder (Crucible Base Separator) to help ease the separation of stands (base blocks) from crucibles and furnace bottoms. Through advanced research, a proprietary highly-conductive formulation has been developed and has been shown to provide a significant reduction in crucible adhesion…
Struers SystemAbele Accessories – Preparing Thin-Sections has never been so easy
Struers offer a wide range of equipment and consumables designed for the preparation of mineralogical samples. In expanding the offering, the new “SystemAbele” which is a unique set of accessories developed specifically to make the preparation of thin-sections faster and easier has been introduced.
Norton SG Blaze Plus R980P belts
Norton has launched the next generation of SG Ceramic abrasive products for metal removal – the re-engineered Norton SG Blaze Plus R980P belts. The new R980P Norton SG Blaze Plus belts have improved base adhesion, for exceptional grain retention, resulting in 30%+ longer life versus original Norton SG Blaze products and an improved Y-weight polyester backing.
Record, visualise and monitor as every measurement value counts!
The new Universal Data Manager Ecograph T RSG35 from Endress+Hauser guarantees a safe and complete recording and visualisation of all process steps, to fulfill the demands on process monitoring and data recording that are becoming more and more complex – as every measurement value counts!
Morgan Thermal Ceramics offers Cerox® fired refractory shapes and engineering expertise for producing clean and contaminant-free metals
Morgan Thermal Ceramics has announced the availability of Cerox® fired refractory shapes, offered in a range of material compositions, including many specifically used for the manufacture of rotating and non-rotating airplane components and automotive turbochargers.
StrikoWestofen introduces mobile website and system-specific QR code identification
The StrikoWestofen Group offers faster system-specific support to their customers. This is made possible by the new mobile website of the company, providing the necessary contact options. A QR code retrofitted to all existing systems allows service technicians to give targeted counselling.
Foam ceramic filters made of highly pure zirconia – particularly high load capacity and very robust
The use of efficient filter systems to remove contaminants and reduce turbulence plays a defining role in the quality of castings. The manufacturer of foundry aids ASK Chemicals provides a comprehensive filter product range for this reason.
Transparency in compressed air networks
The number one choice for measuring compressed air and technical gases in the bulk solids processing industry is the Endress+Hauser’s t-mass 150 thermal mass flow meter, specially designed for use in compressed air and supply networks.
Norton Saint-Gobain Abrasives bring their latest abrasive technology products to South Africa
Norton Saint-Gobain Abrasives bring their latest abrasive technology products to South Africa. Norton Abrasives has developed the Norton Vitrium3 bonded abrasives products, engineered for maximum performance and cost savings in precision grinding.
Auto-deposition coating for ferrous castings
Henkel Corporation introduced a water-based reactive auto-deposition coating — Bonderite® M-PP 930C™ — formulated specifically to deliver a uniform, defect-free surface coating on raw cast components and ferrous metals.
Q2 ION – Ultra-compact Spark-OES metals analyser
An affordable price and low operational costs make the Bruker Elemental´s spark spectrometer Q2 ION elevates metal analysis into new levels of simplicity and ease-of-use. Today Q2 ION is one of the smallest and lightest ultra-compact spark emission spectrometer for metals analysis available.
Omega launches a new range of low cost, high specification coreshooters
Omega has always been well known for its comprehensive range of no-bake moulding equipment and BZV coreshooters, but there has been the need for a low cost option to the jobbing machine range.
Spectrotest mobile metal analyser now features Spectro metal database
Spectro Analytical Instruments now offers direct access to its Spectro metal database on the latest versions of its Spectrotest – the most powerful mobile metal analyser in the Spectro product line.
StrikoWestofen presents new Westomat series and control
The StrikoWestofen Group has redesigned its Westomat dosing furnace with a new “ProDos 3” control system. The dosing furnace was exhibited for the first time at the Euroguss 2014.
Efficient filtration in steel and iron castings
Udicell™ – tubular foam ceramic filters for steel and iron castings. Due to the increasing demands on the quality of today’s castings, especially large and heavy section castings, effective and above all safe filtration during the casting process has become essential.
Bruker G4 Icarus carbon / sulphur analyser
For rapid and precise carbon and sulphur measurements the G4 ICARUS HF, using the combustion method with high frequency induction furnace and infrared detection, proves highly effective…
Saint-Gobain Abrasives foundry products
Saint-Gobain Abrasives, one of the world’s leading abrasives manufacturers, is the only international supplier of abrasives that manufactures each of the three major types of abrasives.
The new Bruker Elemental Q2 ION
Bruker Elemental´s new spark spectrometer Q2 ION elevates metal analysis into new levels of simplicity and ease-of-use. Today Q2 ION is the smallest and lightest ultra-compact spark emission spectrometer for metals analysis available.
Mould coating helps determine drying status
Through intensive R&D, ASK Chemicals aims to provide metalcasting operators with a continuous supply of new and efficient problem-solving techniques. Its most recent development is a fireproof, water-based coating that incorporates a wet/dry colour indicator.
Oxford Instruments launches a portable cordless metal analyser
Oxford Instruments has introduced a new portable arc / spark metal analyser, the PMI- Master Smart. It is the only true portable and full range optical emission spectrometer in the market, designed for metal analysis especially in hard to reach places.
Metal recycling shredder systems – Metso Recycling
Metso Recycling have a long history of designing and implementing bespoke solutions for the metal scrap processing industry. Their solutions encompass all aspects of shredder plant design, from infeed equipment, to the latest in ferrous and nonferrous downstream processing plants.
Endress + Hauser’s Promass E 200 two-wire Coriolis flowmeters
Tired of using mechanical counters? New instrumentation offers smooth integration into your process…and no moving parts. As a long-term user of mechanical sensors such as positive displacement meters or turbines for flowmetering applications…
Oxford Instruments extends range of spark emission spectrometers
The Foundry-Master Xline and the PMI-Master range support foundries and metal producers in determining metal samples fast and accurately, embracing both mobile and stationary analysis needs.
The stationary spectrometer Foundry-Master Xline has been developed specifically to meet the needs of the metals and steel markets.
Automated iron pouring system
The Sert Uceram system available from Foseco is a 100% automated system that increases the speed and efficiency of pouring and molding lines. It will increase an iron foundry’s yield through precision pouring while also improving casting quality. The system can be installed on any pouring vessel (furnace or ladle-type), and any molding line (horizontal or vertical).
Chromite separation solution and equipment – Omega Foundry Machinery
Omega Foundry Machinery have recently supplied chromite separation equipment to a foundry in the UK, a system that provides up to 99% pure reclaimed chromite sand by using a combination of drum magnet separators and a fluidised density separator, according to the company.
Special coating for aluminium die-casting improves service life of dies – ASK Chemicals
For suppliers to the automotive industry, the production of cast aluminium parts by means of gravity and low pressure die-casting is of high technological and economic importance. With precisely these requirements in mind, ASK Chemicals have developed a semi-insulating die coating Solitectm AD 901.
Phenom-World unveils the third generation Phenom desktop SEM
With the introduction of the next generation Phenom ProX desktop SEM Phenom-World confirms its position in the top of the high-end table top for SEM imaging and analysis.
RKC announces the new SA100L limit control with optional din rail mounting
RKC Instruments has introduced the new SA100L 16th DIN limit controller with an optional DIN rail mounting socket.
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