Grinding Techniques offers solutions for your grinding operations in the foundry
Producing quality products at the best possible price remains a key deliverable for any foundry. Keeping input cost under control on the one hand and balancing it against the available market price is a critical business skill. Grinding operations contribute heavily to the total cost of an end product and as in most foundries, grinding wheel costs can vary immensely per ton of castings poured.
Mobile metal analysers: On-the-spot solutions for incoming and outgoing inspection
Is the metal or metal alloy you’re working with the right one? Does it have the chemical composition that your supplier promised, your process needs, your customer demands, or your product requires? Metal mistakes and counterfeits are impacting supply chains worldwide. Accepting the wrong alloy at the shipping dock or on the factory floor can mean anything from a troublesome batch rework to a catastrophic loss of business.
Reducing production costs in large castings through the use of innovative filtration systems
The use of filters offers great potential for reducing costs in the production of large iron and steel castings. It also provides further interesting advantages in the production chain. The use of filter products is critical to the success of foundries around the world. The removal of impurities and the reduction of turbulences by filters are nowadays essential components of every foundry operation.
Foseco’s Vapex Foslow: A solution to rapid changes of nozzle size in bottom pour applications
When using stopper and nozzle technologies for bottom pouring applications it may be desirable to change nozzle diameters between fills of the ladle or even between castings. In normal circumstances this would not be possible as it would require removing and replacing the nozzle and stopper. Foseco’s Vapex Foslow is a new system that allows for changes in nozzle diameter, even in a full ladle.
LIBS vs XRF: Comparing handheld scrap analysers
In recent years, laser-induced breakdown spectroscopy (LIBS) has been used increasingly in foundry and metal recycling applications, especially with aluminium and other nonferrous metals. LIBS is an analytical technique that uses a short-pulse, low-energy laser beam to cause laser ablation, providing sample surface analysis without radiation concerns. X-ray fluorescence (XRF) is a non-destructive technique used to determine the composition of materials.
Morgan Advanced Materials’ customised crucibles for demanding melting applications
Excel and Himelt are high-quality, carbon-bonded, silicon-carbide crucibles manufactured using the latest roller-forming techniques and are designed to cater for a range of non-ferrous melting applications. Excel are intended for aluminium melting in oil-fired furnaces, melting copper-based alloys in gas and oil-fired furnaces, melting precious metals and non-ferrous alloys in low to medium frequency induction furnaces.
Discover the world of portable hardness testing – Emco Test
Emco Test manufacture a wide-range of hardness testing instruments suitable for various applications such as Vickers, Knoop, Brinell, Rockwell, plastics and carbon test methods and the possibility for either single point or advanced, multi-point tests such as case hardness depth, nitriding hardness depth, surface hardness depth, Jominy sample testing and Weld HAZ (heat-affected zone) testing.
Maximise aluminium yield and cut casting costs with a focus on furnace efficiency
Metal loss and excessive energy consumption are two of the biggest threats to aluminium die casting profitability. Depending on aluminium grade, a metal loss of just 1% of an annual melting output of 5,000 tonnes could equate to an average financial loss of 70,000 EUR, while around 25% of the total cost of die cast parts is associated with energy consumption. Both are common issues that can be readily addressed by focussing on melting and dosing furnace processes and efficiency.
High-productivity 3D laser scanner comes to Hexagon’s Absolute arm
Hexagon’s Manufacturing Intelligence division’s RS6 Laser Scanner is a cutting-edge 3D laser scanner for the new generation of Absolute arm portable measuring arm systems that was launched in 2018. This scanner offers extremely high-density point-cloud data collection at high-speeds and high-accuracy. The RS6 delivers unmatched productivity improvements over competing scanning solutions through the introduction of Shine – an advanced set of algorithms.
Metkon Forciplan 102 automatic planar grinding machine
Metkon’s Forciplan 102 is an automatic planar grinder for the first step plane grinding of metallographic specimens. It is designed for first step initial planar grinding of very large specimens or a high volume of specimens in specimen holders. It is fast and efficient in providing high-quality flat specimen surface thus saving time on the subsequent fine grinding and polishing steps. It can easily provide enough specimens for two or three grinding/polishing machines.
Vanta handheld XRF analysers for precious metals analysis
When accuracy and confidence count, Vanta handheld XRF analysers provide immediate, on-site elemental measurements for analysing precious metals including gold, platinum, silver and rhodium. The Vanta portable XRF analysers can be used for alloy and metal sorting, positive material identification, mining applications, environmental assessment, product safety and many more including jewellery analysis, on-the-spot analysis of gold karat percentage, car catalytic converter recycling and old bar analysis.
Reduction of VOC emissions – ASK Chemicals
In ASK Chemicals’ white paper, you can read how VOC-optimised binder systems can be used to reduce emissions in core production. The technical and financial effort to reduce emissions has been increasing for years. This affects all material flows, as well as exhaust air systems, afterburning and disposal of contaminated material (wastewater, sands).The focus on the risks posed by combustion products on the casting line is increasingly giving way to a holistic view of emissions across the entire production chain.
Bruker launches the Q4 Tasman Series 2 advanced spark OES metals analyser
Bruker has announced the launch of the new Q4 Tasman Series 2, a versatile, high-performance spark optical emission spectrometer (OES) for the metals industry. The Q4 Tasman Series 2 extends Bruker’s line of benchtop OES systems, combining reliability and outstanding analytical performance with low cost of ownership. The Q4 Tasman Series 2 employs MultiVision, the innovative dual optics concept, allowing the optimal choice between three variants to fulfill individual analytical needs.
Nexa3D delivers new xCast material for series production of precision metal castings
Nexa3D, the maker of ultrafast polymer production 3D printers announced today the immediate commercial availability of xCast, a new material tailored specifically for the production of precision investment casting patterns on the NXE400 3D printer. xCast is ideal for foundry series production of small, large and complex metal parts for a variety of aerospace, defence, automotive, oil and gas and heavy industry applications, offering a tool less, faster and more accurate alternative to traditional pattern production.
Furnace efficiency – maximise aluminium yield and cut casting costs
StrikoWestofen has developed a new guideline, which helps aluminium foundries to get specific cost drivers under control. The guide shows where problems can occur and which technical solutions are available to solve them. Metal loss and excessive energy consumption are two of the biggest threats to aluminium die-casting profitability. Depending on aluminium grade, a metal loss of just 1% of an annual melting output of 5 000 tons could equate to an average financial loss of 70 000 EU.
Vanta portable XRF analysers from Olympus
The Vanta portable XRF is the next-generation handheld XRF analyser from Olympus. The instrument is one of the toughest devices that Olympus has ever made, and has been designed for use in the harshest conditions throughout the day. The Vanta XRF analysers are revolutionary, rugged, and productive. These powerful and intuitive instruments deliver the right solutions in the toughest working conditions.
Rollover stripping station: Endeco Omega Sinto mould handling
As a leading supplier of complete mould handling systems, Endeco Omega Sinto has the capabilities to deliver rollover stripping stations to suit a multitude of different requirements. They understand the demands of the industry, offering durable solutions built to withstand even the most intense operational conditions. Our stripping stations are suitable for moulds from 500mm x 500mm up to 3 500mm x 2 500mm as standard, however, we can provide bespoke options up to 7 000mm in length.
Software collects downtime and production efficiency data
ShopFloorConnect 6.0 OEE and Shop Floor Data Collection software collect downtime and production efficiency data from every machine in the operation, displaying it in real-time on any web browser including mobile devices, and produces indispensable manufacturing reports, including detailed OEE reports in a variety of formats. The software can increase manufacturing capacity and profitability by identifying and quantifying excessive production losses and bottlenecks, reducing machine downtime by up to 70%.
Selecting and applying risers to optimise casting performance and results
Most metals are less dense in their liquid state than as a solid, so castings may shrink during cooling, which can create a void at the last point to solidify. A riser (also called a feeder) attaches to the mould at the point of molten metal entry, to prevent cavities from forming due to shrinkage during solidification because the last point to solidify is outside the mould proper. A combination of shape and formulation have an important effect on the efficiency of the riser’s performance.
High-performance automatic vision system – LS Starrett
With a highly stable, mechanical design and precision linear bearings, smooth stage motion, maximum performance and throughput are attainable. Throughput is further enhanced by either QC5000 or MetLogix M3 software that controls video edge detection and multiple-channel fibre optic or LED illumination. Computer-controlled Quadrant (LED) ring lighting, sub-stage lighting, and optional through-the-lens lighting meets the most challenging illumination requirements.
Laempe – Big data meets foundry
How data analysis by the Digital Cockpit helps to optimise the core production process. The baseline situation: Core production is subject to a large variety of influences. Especially in core production, there are situations in which apparently identical conditions produce different core qualities. This sub-process in the complex foundry process is subject to a large variety of influences. The main difficulty is that some of these influencing factors are still unknown and some of the known variables cannot be directly influenced.
Foseco’s Dycote Safeguard products extend die service life
The range of Dycote Safeguard products are nano-ceramic top coatings to be applied on top of the existing insulating Dycote base coating. Foseco’s latest range of Dycote Safeguard die coatings increase die operating life by up to three times compared to conventional coatings. Poor die coating service life leads to reduced productivity and increases the risk of rejects due to poor casting surface quality.
Grinding Techniques offers complete grinding solutions for the foundry industry
Grinding is an integral process of removing unwanted material from a casting or workpiece. In today’s industry, the grinding process is used on a broad range of ferrous and non-ferrous metals, and on non-metallic materials from rough snagging and dimensioning to the development of fine finishes. In most aspects, grinding is similar to milling, turning or other metal cutting operations.
Superwool XTRA low biopersistent fibre for iron and steel
Superwool XTRA, a low-biopersistent fibre, meets stringent environmental requirements in addition to high-temperature tolerance and improved pollutant resistance. Lining iron and steel furnaces is critical to extend the life of the furnaces and to protect the purity of the metals being heat treated. Therefore, choosing the best material to meet these needs is crucial.
Metkon’s Micracut sample preparation equipment
Metkon Micracut precision cutters are used for precise and deformation-free cutting of metals, ceramics, electronic components, crystals, composites, biomaterials, sintered carbides and various minerals. Micracut has its place in virtually any metallurgical, geological, electronics, research, biomedical or industrial laboratory. The applications are endless.
PFERD composite brushes for deburring
Industrial brush applications such as deburring or surface finishing are more and more often carried out in a fixed setup situation. Composite brushes from PFERD have been specifically developed for industrial, automated use. They are suitable for a variety of applications and their variable clamping options mean that they can be used on many different drive systems.
O.M.LER decoring benches and hammers
Decoring of castings in a foundry is not one of the most sought-after employment opportunities but is a necessary operation in the foundry. Removal of the core and core residue from the casting is usually done by introducing impact energy (using a hammer or vibration/swinging energy) and the broken mould material is then disposed of or more likely to be sent to a reclamation plant.
Grinding Techniques – moving the automotive industry forward
Global earth warming plays a major role on climate change, in some parts of the world wreaking havoc with uncontrollable bush fires, severe flooding and drought. The major contributing factor being high levels of carbon dioxide that is released in the atmosphere by gas emissions from internal combustion engines.
Alphaset (APNB) – Customised formulations for maximum benefits
D.Ghosh of Forace Polymers, India has written a paper on the Alphaset (APNB) process for mould and core making in foundries, one of the two most widely used self-set processes practiced across the globe at this time. In this paper, attempts have been made to relate few variables in APNB formulations to physical, chemical and sand mix properties, at ambient and elevated temperature.
Belec Vario Lab laboratory spectrometer
The Belec Vario Lab laboratory spectrometer sets a unique standard in terms of precision and flexibility as it has been continuously improved in order to fulfil today’s needs for metal analysis. From small parts to large castings the Vario has no limit on size or shape for analysis. The optional sparking probe allows analysis of over-sized forgings or castings to be easily tested without part destruction.
Power-converting induction melting for aluminium alloys – Inductotherm
Standard aluminium melt furnaces, including electrical resistance (ER), induction, and fossil fuel-fired furnaces continue to be options for melting aluminium. Inductotherm Corp is offering a new method for melting aluminium and other non-ferrous metals that, in many applications, will melt metal quicker, cleaner and more efficiently. The Acutrak® system with direct electric heat (DEH) technology is well suited for foundries, permanent mould casting and die-casting operations.
Bruker Q4 Tasman – the ‘multi-tool’ in metal analysis
Everyone knows the small, handy tool with its many practical functions. It offers many features, is quick and ready for use and needs almost no space. The comparable multi-tool for metal analysis is the Q4 Tasman spark spectrometer from Bruker Elemental.
Making the correct tool choice – Grinding Techniques
In the modern age of industrial innovation, it has become more important than ever to analyse the performance of every tool at your disposal. The margin between success and failure, profit or loss may be determined by the small differences in production times and costs we often take for granted.
Belec Compact Port HLC
The Belec Compact Port HLC is a portable hybrid spectrometer for metal analysis of carbon combined with the unique and flexibile 6GSO-System. What has only been able to be previously done on laboratory spectrometers, is now able to be done on Belec’s latest portable spectrometer generation.
Disa’s mould accuracy controller Disa Mac
Disa’s mould accuracy controller Disa Mac is a high-precision measuring device that captures mould-related mismatch, mould gaps, mould steps and parallelism for each mould before pouring. The Disa Mac helps identify issues around mould alignment before they become a problem – that is, before they result in unnecessary rework or scrapping of one, more or many castings.
Simulation software for autonomous engineering
Recently Magma introduced its new release, MagmaSoft 5.4.1, the MagmaSoft modular simulation software for casting design and optimisation, with numerous new capabilities and improvements for virtual prediction and optimisation for all casting processes, including continuous casting and core production. New release includes a free visualisation function.
Combining toughness, thermal resistance in HPDC die steel
New automotive casting objectives highlight the deficiencies in standard tooling materials, but an alternative promises quality, lower cost, longer tool life, and more. The difficulties of casting high-volume automotive parts are well established, and those issues become more critical in production of critically engineered parts, such as the increasing volume of parts produced by high-pressure die-casting.
Spectro introduces its new Spectromaxx with iCAL 2.0 arc/spark OES analyser
Spectro Analytical Instruments has introduced the eighth generation of its Spectromaxx with iCAL 2.0 arc/spark OES analyser that has been improved with innovative new capabilities and advancements in performance to achieve fast, accurate elemental analysis precisely tuned for material control and foundry applications.
Metkon Spectral Range of spectrographic sample preparation equipment
Optical emission spectrometry (OES) and X-Ray fluorescence are the most commonly used techniques for the analysis of metals and solid samples. Accurate results using these analysis techniques rely heavily upon accurately prepared specimens. Metkon’s spectral range of surface grinders, stone grinders and milling machines are purpose built and offer many benefits such as ease of use, increased user safety and improved results accuracy.
The new Belec In-Spect compact stationary spectrometer for metal analysis
With the completely redesigned metal analyser Belec sets new standards. The all new Belec In-Spect, with its unique dual-spectrometer optics guarantees unbeaten performance in conjunction with significantly reduced maintenance costs in this instrumentation class, says the company. The Belec In-Spect is a compact stationary spectrometer for metal analysis.
Simpson Technologies: Reliable and repeatable sand testing solutions for small to large foundries
Casting defects not only affect quality, they impact your profit margin and competitiveness too. Unfortunately, recognising casting defects is one of the most challenging burdens confronting metalcasters. The good news is there is an answer for every defect. Imagine having the right sand testing equipment instrumentation in your laboratory to give you the analysis you need to better control your materials and processes to reduce defects.
Process control by analysing metal temperature gradients with fixed thermal imaging
Producing metal products is one of the most energy intensive industries. Improving both energy and production efficiency, as well as ensuring product quality is at the top of any manufacturers to do list. As new technologies, such as fixed thermal imaging cameras, continue to advance, it’s becoming easier than ever for engineers to gather the data they need to understand and optimise their manufacturing process.
Morgan Advanced Materials customised crucibles and foundry products for demanding melting applications
The Molten Metal Systems (MMS) business of Morgan Advanced Materials has successfully developed extra-large ISO-pressed crucibles, with a capacity to hold up to three metric tons of molten metal. Morgan can also enhance crucible sizes to hold between six and ten metric tons of molten metals for specific melting requirements. This development has been made possible using one of the world’s largest Cold Iso-static Presses.
Altair launches all-in-one industrial design solutions Inspire Studio and Inspire Render for optimised 3D modelling
Altair Inspire Studio enables designers, architects and digital artists to create, evaluate and visualise design ideas faster than ever before. Altair has launched its new 3D design and rendering solution Altair Inspire Studio. Each tool and workflow are now optimised for an efficient design experience from initial sketches to exploring styling with freeform.
Longer lasting crucibles for aluminium – Morgan Advanced Materials
High density, clay-bonded, iso-statically pressed crucibles have a high graphite and silicon carbide content. Morgan Advanced Materials credits ‘a technological advance in materials science’ for new series of crucibles developed by Morgan’s Molten Metal Systems business, claiming these units will last more than 50% longer than previously available crucibles used for aluminium casting.
Bruker’s XRF PMI guns and Q2 ION spark emission spectrometer
When it comes to Positive Material Identification (PMI), Bruker provides a fast, easy and completely non-destructive analysis method for every metal component: XRF PMI guns. Whatever industry you are in, Bruker’s Q2 ION is one of the smallest and lightest ultra-compact spark emission spectrometer for metal analysis available today.
Foseco’s Semco IC – A new foundry coating improving inner cleanliness for the latest engine technology
Today the influence of a coating applied at a thickness of about three human hairs goes way beyond the actual cast component. It can beneficially improve the surface roughness resulting in an improvement of the performance of the engine and extend the service interval frequency of modern combustion engines.
Hexagon high-productivity 3D laser scanner
Hexagon Manufacturing Intelligence has introduced the RS6 Laser Scanner for the new generation of Absolute Arm portable measuring arm systems launched in 2018. It offers extremely high-density point-cloud data collection at high speeds and high accuracy. The RS6 delivers productivity improvements over competing scanning solutions through the introduction of SHINE, an advanced set of algorithms.
Morgan Molten Metal Systems launches a next generation, ‘game-changing’ crucible for holding molten aluminium
The newly developed VAluStar crucibles by Morgan Molten Metal Systems have a significantly longer life than other iso-statically pressed crucibles for lower temperature applications and retains its good thermal conductivity over the entire life. Morgan Molten Metal Systems (MMS) has been manufacturing crucibles for non-ferrous metals for more than 160 years.
Discover the world of hardness testing – Emcotest
Emcotest manufacture a wide-range of hardness testing instruments suitable for various applications such as Vickers, Knoop, Brinell, Rockwell, plastics and carbon test methods and the possibility for either single point or advanced, multi-point tests such as case hardness depth, nitriding hardness depth, surface hardness depth, Jominy sample testing and Weld HAZ (heat-affected zone) testing.
Magma presents a new generation of solutions for virtual casting
MagmaSoft autonomous engineering supports casting design, robust process layout and optimised casting evaluation even before the first part is produced. By making use of the fully integrated capabilities of virtual Design of Experiments and genetic optimisation, MagmaSoft easily and reliably finds the best solutions, from the first casting design to improvement of a running production layout.
Norican Digital’s Refill Monitor
Norican Digital has launched its digital product Refill Monitor which, uses real-time sensor data to improve the productivity and uptime of casting lines. The system is also simple to install on existing facilities. Refill Monitor uses sensor generated data to ensure dosing furnaces (e.g. Westomat) or bale-out furnaces never run low on metal, maximising machine productivity and uptime.
Bühler’s Digital Cell is a step change for the die-casting industry
Bühler Die Casting has introduced the Digital Cell, a solution that aims to deliver 0% scrap, 40% less cycle time, and 24/7 uptime to make the die-casting industry more profitable and efficient. Three solutions launched GIFA 2019 form part of the future Digital Cell, the first of which will be every future Bühler die-casting cell’s smart digital brain – the SmartCMS (Smart Cell Management System).
Metkon spectrographic sample preparation equipment
Sample preparation starts with cutting and good cutting means a good start. Selecting the right cut-off wheel ensures freedom from burn and distortion and is the best way to save time and consumables. Correct cutting produces specimens which are in perfect condition for the next preparation steps.
ASK Chemicals presents its solutions for 3D sand printing
With 3D sand printing using the powder binder jetting process, production of sand cores using contour-forming models and core tools is eliminated. The geometry of the sand cores is initially developed digitally based on CAD models. Next, the recoater applies a layer of a few hundred micrometres of quartz sand fully automatically. Then the binder liquid is selectively applied to the sand bed via the print head.
Altair Inspire Cast: Streamlined casting simulation software inspires you to avoid defects
Due to increasing requirements, such as shorter time or new regulatory requirements, companies must adapt their development processes to produce high-performance products that are weight-, material- and cost-efficient. This can be achieved with innovative software tools such as Altair Inspire.
New specialty inoculant for grey iron – Elkem
Elkem has launched a new high-aluminium inoculant that, according to the experience of foundries maximises chill reduction, reduces casting porosity, and increases the tensile strength of grey iron castings. The new Superseed® Extra Al Inoculant contains a special combination of aluminium, strontium, and zirconium that eliminates chilled white iron in thin sections and corners, increasing the machinability of grey iron castings.
Hardness testing of metal components: DuraScan G5
With the DuraScan G5 family, all Vickers, Knoop and Brinell test tasks in the load range between 0.25gf and 62.5kgf can be performed efficiently, flexibly and reliably. All model versions excel with the innovative user guidance system of the ecos Workflow operating software. The test cycle from setting the indent through to displaying the hardness value is always performed fully automatically, thereby eliminating operator effects to the greatest possible extent.
Sandman data analytics software to reduce rejections and optimise additives consumption in green sand foundries
The data analytics software presents the state of green sand parameters, its process control and correlation to related rejections. Sandman provides a tool to understand the dynamic and continuous state of process optimisation of the sand system and predicts the corrective action required to control the sand parameters.
Sandvik additive manufacturing to advance binder jet manufacturing
TThe ExOne Company, a global provider of three-dimensional (“3D”) printing machines, 3D printed products, and services to industrial customers, announced a further strengthened material collaboration with Sandvik Additive Manufacturing, a division in the high-tech global engineering Sandvik Group.
Akasel Diamond suspensions for metallographic preparation
Akasel diamond suspensions have been developed to combine quick preparation with reproducible results. They have been formulated with environmentally friendly components. In a special process, Akasel suspensions are de-agglomerated. This assures outstanding finish without large scratches from agglomerated diamond particles.
A framework for rapid additive design and manufacturing: Subtraction before addition
Although the impetus for weight reduction in aerospace compelled engineers to look deeply into topology optimisation methods to generate bionic-designs that were elegant and optimised for performance, the recent advances in 3DPrinting methodologies are enabling naval and marine industries to benefit immensely from the same quick re-design and rapid manufacturing of components.
Miratec TC technology shows best performance in turbocharger casting
ASK Chemicals has developed a zirconium-free coating technology with Miratec TC. As a result, users are less dependent on rising raw material prices and benefit from a product that is in no way inferior to the performance of zirconium coatings. To meet increasingly stringent carbon regulations, a rethinking of drive concepts is required for the long-term.
Bruker launches the G6 Leonardo analyser for oxygen, nitrogen and hydrogen (ONH) analysis by inert gas fusion
At IFEX 2019, Bruker announced the launch of the new G6 Leonardo, an economic and robust inert gas fusion (IGF) analyser for oxygen, nitrogen, and hydrogen (ONH) concentration measurements in inorganic samples. The G6 Leonardo extends Bruker’s line of high-precision, compact and easy-to-maintain analysers.
New material from Morgan Advanced Materials shortens production time of turbine engine blades
Morgan Advanced Materials has developed a proprietary leachable material which significantly cuts investment casting times in turbine engine blades by up to 20 per cent. The development comes as the commercial aerospace industry is facing a significant overhaul. According to Market Research Future, the Commercial Aircraft Turbine Blades and Vanes Market is forecasted to grow at a CAGR of 6% by 2023.
Fluorine-free material for feeder systems
HA International is introducing fluorine-free material for feeding systems developed by Chemex GmbH (part of the HA Group) that it said delivers a shrinkage-free product and increases casting productivity, even for complex designs. The material composition also results in reduced surface defects, and the new product line allows feeder placement in previously inaccessible locations, HA noted.
New Wheelabrator hanger-type blast machine features strip out costs while increasing efficiency
Ideally suited to light to medium-duty tasks in forge and foundry environments, the HTS range offers economical blasting of a variety of castings, forgings or heat-treated parts in highly flexible overhead monorail layouts (reversing Y-rail, closed-loop through-feed). The machines integrate seamlessly into existing workflows and can cover a broad range of handling requirements.
Bruker launches G4 Icarus Series 2 combustion analyser for high-sensitivity carbon and sulfur analysis
Bruker has announced the launch of the new G4 Icarus™ Series 2, a versatile, high-sensitivity combustion analyser for carbon and sulfur concentration measurements in inorganic samples. The G4 Icarus Series 2 extends Bruker’s line of compact, high-efficiency and low-maintenance combustion analysers by introducing novel, high-sensitivity detection technology in combination with a unique, industry-proven furnace.
Castings from housings to flanges: An affordable moulding line for small foundries worldwide
Global casting production continues to grow. In percentage terms, the growth rates for aluminium castings are certainly higher than those for the other alloys, but more than 70% of all castings are still produced in iron: Nodular, malleable and grey iron. In the major countries, this part of the market has been subject to a continuous concentration process. Large foundries and foundry groups expand their capacities to adapt to the cost pressures from the automotive industry.
Fluorine-free material for feeder systems
HA International is introducing fluorine-free material for feeding systems developed by Chemex GmbH (part of the HA Group) that it said delivers a ‘shrinkage-free’ product and increases casting productivity, even for complex designs. The material composition also results in reduced surface defects, and the new product line allows feeder placement in previously inaccessible locations, HA noted.
Mobile heating to guard against thermal shock – StrikoWestofen
StrikoWestofen’s newly developed mobile heating station allows ceramic components to be heated directly on site, meaning that riser tubes, filling funnels, etc., can be carefully heated to the ideal temperature of 400°C immediately before use. To date, this heating process is often performed incorrectly and haphazardly, risking damage to the ceramics and injury to foundry workers.
Monitoring system for vibratory de-coring – O.M.LER SRL
Networkable interface collects data from integral sensors to monitor vibration, strokes, frequency coordinates with pneumatic de-coring hammer PLC relay outputs, or Ethernet / Profibus Touchscreen panel, intuitive HMI. Italian manufacturer O.M.LER SRL specialises in pneumatic systems for vibratory de-coring of grey iron and aluminium castings. Following its earlier development of the AF1470 pneumatic de-coring hammer, it has introduced a coordinated process monitoring system.
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.