GIFA '03: unveiling new technology casting advancements: with more than 40,000 attendees searching for the latest and greatest technological advancements in metalcasting, this year's GIFA delivered the future of metalcasting for all to behold.

GIFA is the metalcasting industry's largest event. Hands down, no competition.

The 2003 version of this once every four-year conference drew more than 40,000 attendees to Dusseldorf, Germany, June 16-21, as industry suppliers from across the globe showcased the latest technology--the focus of GIFA. Many of the industry's suppliers hold off on introducing new technology just to make a splash at GIFA and earn valuable booth time from its foundry attendees. On the other hand, some suppliers will rush innovations through the development phase just to be able to have new technology for attendees to "ooohhh" and "aaahhh" over.

This year's event was no different.

While attendance at the overall show (which also included NEWCAST for casting designers and purchasers, METEC for metallurgical technology and THERMPROCESS for industrial furnaces and thermic production processes) was down from 96,000 visitors in 1999 to more than 70,000 this year, the mood was one of excitement over a growing global metalcasting industry. The entire show featured more than 1661 exhibitors from 43 countries (with GIFA hosting 793 exhibitors). In addition, the World Foundry Organization Technical Forum was held for two days during GIFA with presentations focused on information technology for foundries and the various approaches being taken worldwide in simulation processes and process automation.

This article provides a review of much of the technological innovation showcase at GIFA '03. As North American foundry officials who have attended the show can attest to, it is nearly impossible to encompass the entire seven-building GIFA event. However, this sampling, which also includes information posted through the MODERN CASTING GIFA Diary at www.moderncasting.com, should pave the road for the readers of MODERN CASTING unable to make the trip to Germany.

Readers interested in more information on any of the technology discussed in this review can make their requests in real time online at www.moderncasting.com/info to receive a faster response. Additional coverage of many of these technological innovations also will be featured in the product innovations pages of future issues of MODERN CASTING.

Coremaking

Laempe introduced an all-new Beach-Box binder to offer a new solution to environmental and disposal problems. The new core and mold binder allows for a 100% closed circuit without emissions or odors and decoring can be accomplished within seconds. In operation, this magnesium-sulfide-based binder is mixed with silica sand and heated. Using a patented mixing process, it is shot into warmbox tooling to produce the core/ mold. Used core sand simply needs to be mechanically reclaimed and dissolves in water.

Currently used in two German foundries, the Beach-Box binder is achieving cure rates, cycle times and strengths that are equal to coldbox binders. According to the firm, it is the only supplier offering a total solution--binder and coremaking technology--for the inorganic binder in hopes of streamlining the development and production process. At GIFA, Laempe made cores and molds and poured castings with 1/8-in. wall thickness on the show floor, demonstrating the odor-free production and the ability to pour without the need for environmental equipment.

Select No. 058 at www.moderncasting.com/info

Ashland Casting Solutions (a business unit of Ashland Specialty Chemical Company) exhibited its range of binder solutions for the global foundry industry along with success stories of them in use. These included:

* Isoset 2000/Thermoshield, a higher hot strength epoxy binder system that does not require a separate addition of peroxide and offers improved dimensional stability, making it possible for casting without coating;

* Isomax 2000/New Generation, a dimensionally stable coldbox system that is an alternative to the shell process for hydraulic valve castings (physical properties provide good aluminum shakeout and make it possible for casting without coating);

* Engineered Sand Additives, which are organic and low emission inorganic systems that allow foundries to produce castings without coatings, low or no veining, low gas for inorganic systems and less penetration. Users benefit from excellent results in conjunction with castings.

Select No. 025 at www.moderncasting.com/info

Foundry Automation's GIFA exhibit showcased its new patented system from MEG Hydrobond for the completely inorganic production of foundry cores. According to company officials, the Hydrobond inorganic binder system addresses the growing technical and environmental requirements for foundry binder systems. This system is characterized not only by the fact that it does not give off any emissions during core production, storage, pouring and decoring, but also by its easy recycling. This means mat me cores are water-soluble, resulting in an easy and product-saving decoring process. The used sand may be recycled nearly in its entirety.

One of the main advantages of this process compared to other processes is the fact that there is no need for a microwave drying oven or amine catalyst gas to harden the cores. Also, there is no need for an exhaust air treatment. This results in significant savings in terms of capital investments and energy for the whole production. The environmentally friendly Hydrobond core binder (available through Foundry Automation) is 100% inorganic and water-soluble, bringing ease to decoring and recycling. It is currently used for 80% of the cores at Germany's Grohman foundry.

Select No. 040 at www.moderncasting.com/info

Fata Aluminum's GIFA exhibit showcased two families of equipment--machines to take advantage of the new GMBond Process and the Peterle line of foundry equipment. The organic GMBond protein-based core binder system (consisting of an animal byproduct and marketed by Hormel Foods) has received attention for its promise of reducing gas emissions during the casting process. In operation, a small percentage of water is added to the sand/protein mix and the core is hardened by blowing in hot air, which subsequently removes the water from the mix. In addition to the environmental benefits afforded by the non-polluting binder, cores can be shaken out from castings simply by dipping them into water. Another advantage of the protein-based binder system is that with its solubility in water, scrap cores and/or core parts not affected by the thermal impact of pouring can be broken up and reused after adding a suitable amount of water (without any need for further treatments).

Fata Aluminum has designed and developed sand systems, core shooters and coreboxes dedicated to the production of cores using GMBond. The first dual-station shuttle-type production system will be installed this year at General Motors Powertrain Saginaw Metalcasting Operations in Saginaw, Michigan.

In addition, Fata Aluminum is showcasing numerous production machines from Macchine Peterle, including equipment for shell molding/coremaking, coldbox, hotbox and integrated cell arrangements. The firm also announced its new partnership agreements with the Italian firms Borli (for low-pressure permanent mold casting machines), Botta Engineering (for aluminum melting/holding furnaces) and Belloi & Ramagnoli (for iron casting systems and green sand controls.)

Select No. 036 at www.moderncasting.com/info

Hottinger Systems focused its GIFA presence on two different areas--core production and core inspection.

Core production highlighted the firm's CB-32-HA coremaking system, which handles a 50 x 50-in. corebox and does not require a foundation. The firm's upgraded core system now comes with closed loop controlled movement, reducing the dry cycle time to 18 sec. The system also has automatic tooling change and shooting head change options. Hydro Aluminum Alucast GmbH has ordered seven of these systems for the production of V6 engine block precision sand packages.

In terms of core inspection, the firm was highlighting upgrades to its vision systems, which utilizes shadows and the direction of light to assist in detecting defects in core production. The firm was running a vision system developed for brake discs that incorporates a conical mirror with a robot to rotate a brake disc core 360 degrees to allow complete inspection in seconds.

Select No. 046 at www.moderncasting.com/info

Ruperwerk showcased its stream-lined coldbox core system for the small and medium run jobbing foundries. The FCJ 12 can utilize either horizontally or vertically split coreboxes and is an advancement from the firm's H 12 model.

Select No. 082 at www.moderncasting.com/info

The Swiss firm Luber showcased its core coating systems consisting of an automatic processing system that features an agitating container, circulating pump, water pouring equipment and an electric control panel and a dip tank for robotic dipping within an area of 1000 x 800 mm.

Select No. 062 at www.moderncasting.com/info

Sand Molding

Denmark's DISA Group announced during GIFA a contract for the delivery of a jumbo-sized DISA 280B vertical green sand molding system. It will be delivered to a foundry in Spain in July 2003.

Designed for the production of exceptionally large castings, the DISA 280B enables production of molds measuring 850 x 1200 mm, making it the largest vertically parted green sand molding system ever produced. The 280B is significantly larger than the firm's largest current model, the 250D, which handles 700 x 950 mm mold sizes. This new jumbo-sized molding system provides a space-saving, high-capacity and high-quality alternative to conventional horizontal molding lines. It works on the same Disamatic vertically parted molding principle of blowing green sand into the mold chamber, which is subsequently squeezed into flaskless molds.

In the inaugural installation, the DISA 280B is replacing a horizontal green sand molding line of a similar flask/box size. The foundry is making the switch to gain competitiveness through productivity gains and enhanced casting quality. These improvements are fundamental to the foundry's success in its market sector. The contract includes the design and changeover of existing horizontal patterns to a vertical orientation. This assures that the foundry will be able to continue to use more than 98% of its existing patterns. The foundry expects to begin production without any compatibility problems as the new line takes the same position of the existing mold line on the foundry floor.

Also on display at the DISA exhibit was the 240 DISA machine that will be installed at Intat Precision, Rushville, Indiana.

Select No. 034 at www.moderncasting.com/info

Heinrich Wagner Sinto (HWS) has introduced a innovation in the field of data acquisition and data processing for foundries--the P.D.C. 2010 (Plant Data Collection). HWS has developed this system for making the complex sequence visible in view of the data technology, and offers optimal possibilities for quality inspection and process optimization.This new development is in operation at Daimler Chrysler/Mettingen and has already proven itself successfully in production.

HWS also introduced the new ACE-series tight-flask molding machine to produce thinner and lighter castings by minimizing draft. This is possible through a superior green sand mold with a uniform density and a high strength, as well as mold stripping property. Users have found energy consumption to be reduced by as much as 60%. Spill sand during filling is virtually nonexistent. The volume of sand required for mold filling is precisely controlled by a feedback system that dramatically reduces the sand scraped off from the mold back face. The ACE series is a compact machine that requires no pits. Four different models are available. When operated simultaneously, mold rates of up to 300 molds/hr are achievable.

Select No. 044 at www.moderncasting.com/info

Loramendi showcased its new and improved Bull vertical molding system, which was first unveiled at the last GIFA. Among the unique new features of the system is its enhanced sand compaction system. A stronger precompaction blow feature is followed by the squeeze to achieve up to 22 Newtons of mold hardness. The machine provides a more uniform mold throughout, including up to the edge of the mold. Improvements have also been incorporated so that a foundry could produce two different pattern size envelopes with only a 20-minute tooling change. The new molding system on display at GIFA is headed to Fundiciones Caetana, Sevilla, Spain.

Select No. 061 at www.moderncasting.com/info

One of the focuses of IMF's booth was the advancements to its nobake sand mixing systems. Dubbed "Total Control" systems, these mixers allow operators to manage their entire operation through an interface on the operator's panel. Two recent advancements in control are the sand weighing system and the flowmeters. The weighing system provides the continuous measurement and control of the quantity of discharged sand. The flowmeter measures the supply of resin and catalyst at any specific moment.

In addition, the firm displayed a 2000 x 3200 mm-size flask nobake line being delivered to Chen Hsong Holdings, Ltd. of China and a nobake sand mixer measuring 3800 mm in arm length being delivered to the Russian foundry Uralvagonzavor.

Select No. 048 at www.moderncasting.com/info

Kunkel Wagner demonstrated its molding production with dry run cylces on an APM-AD Airpress Plus 2000 green sand molding line. Displayed with a flask size of 1000 x 800 x 350/350 mm and mold production of 60 molds/hr, the cope and drag system performs precompaction with airflow and final compaction via squeezing (155 N/cu cm) by a controlled multi-piston squeeze head. This multi-piston head offers a free parameterization of the squeeze forces and delay time between the squeeze circuits. The compensating squeeze rams arranged in groups ensure a homogenous strength distribution over the back of the mold. The preset delay time allows a vertical sand adjustment to increase density at the critical points in the mold.

Select No. 054 at www.moderncasting.com/info

Hunter Automated Machinery Corp. exhibited as part of the North American Pavilion. The firm showcased the continual upgrades to its G and H-series molding systems, including increased accuracy and squeeze pressure for better mold hardness. In addition, the firm focused on its automatic coresetters and turntable and linear mold handling systems that optimize available floor space.

Select No. 047 at www.moderncasting.com/info

Bridging the gap between sand foundries and investment shops, Unicast displayed its ceramic core process that allows sand foundries to economically compete for high surface finish components. The process introduces a molded ceramic core into traditional sand molding to obtain a smooth, precise internal cavity in components such as impellers where pump efficiency demands higher qualities. Slurries used in the ceramic core process are based upon modified ethyl silicate binder and a ceramic aggregate of controlled density and particle size distribution.

Select No. 093 at www.moderncasting.com/info

Carbo Ceramics offered GIFA attendees its first look at the firm's upgraded Accucast ceramic media products to replace traditional molding media in sand molding applications. This media possesses a low coefficient of thermal expansion with adequate tensile strengths to improve component dimensional accuracy. The products' high fowability increases opportunities for thin wall castings. The media is offered in an intermediate and low-density line and can be used with all metals and molding processes.

Select No. 029 at www.moderncasting.com/info

Permanent Mold & Diecasting

Muller Weingarten showcased live demonstrations of its new Opticast 1000 diecasting system, a new small chamber entrant by the firm. At the heart of the technology is a hydraulic system and control concept that achieves closing forces from 5500-17, 500 kN. A new frequency-controlled drive system enables high speeds during the closing and opening stroke. Cycle times are reduced due to the system's optimum motion sequence.

Select No. 074 at www.moderncasting.com/info

ASCO displayed its A90P-D3 system for dry ice blasting of permanent molds. With a production capacity of 90 kg/hr of 3 mm diameter dry ice pellets, the system is geared toward small- and medium-run permanent mold and diecasting foundries that clean their molds by hand or robot. The system has a preset control function to stop dry ice production when high levels are reached and restart production when low levels are attained.

The supplier also highlighted its recent installation of its dry ice blasting system at Ferrari's casting facility in Marenello, Italy, that cyroblasts aluminum molds at speeds up to 300 m/sec to remove coating, carbon deposits and hydrocarbons.

Select No. 024 at www.moderncasting.com/Info

C.P.C., Inc., showcased two new counter pressure casting systems on delivery to foundries in the U.S. and China, including a CPC 1500 system that was going to be delivered to Intermet for the production of aluminum steering knuckles. An advance from previous systems, this model used four cavity molds with six feeding paths to cast four knuckles at one time. The CPC 1300 system on display was sold to Verkaaft AN and the Wang Ferg Group in China.

Select No. 032 at www.moderncasting.com/info

IMR's focus on gravity and low-pressure permanent mold casting systems led the firm to display and run dry cycles on a complete, automated gravity permanent mold pouring and casting cell. The system consisted of a single furnace with a linear automated pouring system. The permanent mold casting system rotates the mold from 0 to 90 degrees for pouring and then an additional 0 to 90 degrees for dipping for mold cooling. The die opens to allow an operator to insert cores and for casting rejection. The dipping tanks supplied with the system are stainless steel and the machine is complete with water temperature control.

Select No. 049 at www.moderncasting.com/info

Fill Technik der Zukunft provided GIFA attendees futuristic looking permanent mold casting with its Tiltcaster TCS. Designed for large castings with weights up to 12,000 kg, the casting system's tubular design rotates from 0 to 90 degrees during pouring (the whole machine rotates) to ensure more turbulent free metal. The system can handle molds up to 4 x 3 x 2.6 m with a mass up to 4000 kg. To ensure against runout, the system uses a clamping force of 12.5 kN.

Select No. 037 at www.moderncasting.com/info

Kurtz ran dry cycles on a low-pressure permanent mold casting system being delivered to the German firm KS Aluminum Technologie AG for the production of V8-V12 aluminum cylinder blocks. The firm also discussed its new low-pressure casting control system that can be retrofitted on old casting machines to assist in the regulation of casting time and pressure.

Select No. 055 at www.moderncasting.com/info

KWC ran dry cycles of its low-pressure permanent mold casting systems for copper-base alloys. With cycle times from 30-50 sec, the firm's systems can produce up to 900 castings per eight hr shift. In its most automated applications, these systems can have one furnace with a linear automated pouring unit feeding three casting machines with automated die cleaning and coating processes. These systems also have automated die changing operations without interrupting the casting cycle.

Select No. 057 at www.moderncasting.com/info

Taylor's HPM Div. introduced new standard controls for its line of diecasting systems. Now using Siemens PC-based TC03 system, these systems are more readily available for consistent global support from the supplier. These control systems use touch screen controls and can be networked and monitored from a single PC station.

Select No. 090 et www.moderncasting.com/info

Kuka and Copras International showcased new automation designs for high production permanent mold casting in which the robot controller manages and integrates all the actions (mechanical, electrical and software-related) of the casting cell including the casting machine and furnace. The consolidation into the robot simplifies the data collection and enhances cell performance. The robots can be utilized as six or seven axis designs and can handle a payload of up to 120 kg of aluminum.

Select No. 052 at www.moderncasting.com/info

The Italian firm Low Pressure Machines showcased its low-pressure permanent mold systems BPB800 and BPC600. With furnace capacities of 600 and 800 kg, the key to these casting systems is the ability to shuttle the holding/pouring furnace in and out for easy riser stalk installation. At its booth, the firm also displayed a 26-in. aluminum wheel cast on its systems by Lenso Wheel in Thailand.

Select No. 059 at www.moderncasting.com/info

Senator Technology GmbH displayed its line of permanent mold casting equipment, including its various designs for automatic aluminum pouring systems. These pouring system designs run from the DK 100 to the DK 200 and can pour castings from less than a kilogram up to 50 kg. The various designs include stationary pouring, turntable designs, linear movement and portable pouring robots to serve multiple furnaces (up to 6) in one cell.

Select No. 085 at www.moderncasting.com/info

Ferrous Melting, Pouring & Analysis

Inductotherm's exhibit introduced GIFA attendees to a wider range of automated pouring systems available through the combination of technologies and engineering recently acquired from DISA (formerly Georg Fischer). The combination brings together experience gained from more than 250 automatic pouring installations worldwide. As a result, foundries now have more automatic pouring system (control systems and vessels) choices to remain competitive. The GIFA product offerings run the gamut, from the basic operator-actuated stopper rod systems to the advanced Visipour control technology.

Select No. 051 at www.moderncasting.com/info

Of particular interest at Foseco's exhibit was the new Stelex PrO (priming optimized) filtration product developed specifically for carbon and low-alloy steel castings. With its new ceramic structure, it eliminates the priming limitations that are inherent to zirconia-based ceramic filters. In operation, this technology creates filter-clean castings and minimizes turbulent metal flow during mold filling. Performance and lightness are not incompatible, said company officials, and in fact this is the basis for the peculiar attributes that can give steel foundries the edge they are seeking. Product features include: low weight, low heat capacity, low firing shrinkage (4-5%), slag resistance, thermal shock resistance, low levels of internal stress, exceptionally high creep resistance and high levels of hot strength.

Select No. 039 at www.moderncasting.com/info

Talvic is a Selee's new ceramic foam filter-inoculant product designed for the treatment of gray iron. The development of inoculant materials (via Pechiney) specially designed to dissolve uniformly and predictably within a Selee ceramic foam filter has created the ability to tailor products to individual casting applications.

By placing an inoculant with a predictable and uniform dissolution rate in a foam filter, the iron can be effectively treated just before it enters the casting cavity. This simple to use system allows foundries to efficiently produce castings that are free from subsurface nonmetallic inclusions.

Inoculation can now be pattern specific, and a variety of inoculants can be designed to tackle unique problems in a foundry. For example, inoculants have been developed to reduce chill, increase Type A graphite, improve mechanical properties and eliminate shrinkage.

Select No. 084 at www.moderncasting.com/info

LMI Technologies' exhibit focused on its new Selcom XLine sensor for molten metal level measurement and control. According to the firm, this line combines the latest advancements in digital sensing, advanced image processing and laser line projection to provide precision measurement capabilities that are unaffected by smoke, steam and other hostile environments. This technology, says company officials, will provide metalcasters with even higher levels of improved quality, productivity and safety.

The line is the first family of digital imaging sensors specifically designed for molten metal applications. Digital laser line sensing is a major step forward in molten metal level sensing, and the XLine provides more data than single-point lasers, resulting in much more reliable information. Available in a variety of configurations, XLine applications include diecasting, continuous casting, launders, foundry wells and holding furnaces.

In addition, the firm unveiled a short-pour detection (SPD) system that is also based on line laser technology. These SPD systems are located downstream from the pour station and detect incomplete fills caused by short-pours or broken molds. Nonconforming molds can then be tracked and automatically or manually removed from the line.

Select No. 060 at www.moderncasting.com/info

CarbSic was a new product promoted by Superior Graphite at GIFA. Superior Graphite developed a new electrothermal process to convert sand and coke into a microcrystal-line form of B-SiC embedded in a graphitized coke matrix. The result is an inoculant called CarbSic, which has unique properties for gray and ductile iron. With typical values of 75% carbon and 25% silicon-carbide with a 0.2-3.0 mm particle size, this inoculant: reduces total consumption; improves inoculant effectiveness; promotes Type A graphite; reduces Type E graphite; modifies tensile strength and hardness; provides more uniform distribution of graphite flakes; and offers significant chill reduction. Select No. 089 at www.moderncasting.com/info

Allied Mineral Products introduced its Fiber Reinforced Dry-Vibe refractory for aluminum, zinc and galvalume (zinc-aluminum melting). In operation, this technology strengthens the cross section of the refractory and minimizes cracking due to thermal shock. Thermal shock is a difficult, time-consuming and expensive operational problem that can easily occur with low melting-point alloys. The firm is also developing the technology for copper-base melting. In addition, the firm highlighted the net benefits it now offers as a result of the recent acquisition of Chicago Firebrick.

Select No. 023 at www.moderncasting.com/info

Vesuvius Group introduced a new continuous temperature measurement system for automatic iron pouring systems. Termed the Monoprobe, this system continuously reads iron temperatures in real-time inside the pour box of an automatic pressure pour system. The measurement system consists of a temperature probe immersed in the metal bath adjacent to the casting nozzle. The probe is connected through a signal cable to an electronic control panel from where the temperature signal is relayed to visual display units and temperature recorders. The full analysis of the temperature profile achieved with this system allows better understanding of pouring dynamics.

Select No. 094 at www.moderncasting.com/info

ABB's GIFA exhibit featured the European premiere of the Smart FS medium-frequency induction furnace. This unit, with a 660-1760 lb volume, is designed to fit into small, flexible foundries offering niche or precision castings or, in the case of larger foundries, as a pilot operation melter. In addition, ABB showed for the first time its industrial-based solutions for robot automation. According to the firm, robot-based automation for cleaning of castings (ranging from cutting gates to deburring to deflashing) are an attractive alternative for forward-thinking foundries. ABB's new TeachSaver software product allows programming time to be cut significantly (up to 90%). As a result, ABB expects the technology to open new possibilities for the automated cleaning of smaller batches and complex parts with a high cleaning content.

Select No. 022 at www.mederncasting.com/info

Spectro Analytical unveiled its new Spectrolab at GIFA. In addition to modernizing the instrument design, an improvement of the analytical performance was a focal point of the new product development. Among these areas was the excitation source. Instead of the earlier analog source, the new unit now uses a digital, programmable Source 3000. This new excitation source results in a dramatic improvement in reproducibility of the measurement results and extremely shortened measurement times. For standard applications, measurements are delivered in 18 sec or less. In addition, the new unit uses 45% less argon and incorporates features that extend machine uptime as well as make necessary maintenance easier and quicker.

Select No. 087 at www.moderncasting.com/info

SLS Engineering showcased upgrades to its Puma pouring robot to increase efficiency. Designed using a modular concept, the pouring system allows a foundry to operate in a semi- or fully automatic state. Using a combination sensor scan for optical measurement of the level of melt in the pouring cup as well as poured weight control to finish mold pouring, the system is able to increase yield per ladle, reducing waste.

Select No. 086 at www.moderncasting.com/info

Calamari highlighted its medium frequency melting furnaces that operate from 150-10,000 Hz. Touting their furnaces high power with high melting speeds, the finn points to its Thyristor frequency converter that changes low frequency power to medium frequency. The furnaces are comprised of three independent sections: the metal foundation frame; the stainless steel support and tilting frame; and the interchangeable inductor with the coil made by a specially shaped copper tube.

Select No. 028 at www.moderncasting.com/info

EGES International displayed its new Ultramelt EGP-S and EGP-SH induction melting furnace with 10-30 ton melt capacity. To reduce maintenance and increase efficiency, this furnace uses an induction rectangular cross-sectioned copper coil with a minimum conductivity of 58. If metal does penetrate the coil, it can be easily dismantled due to the modular concrete design of the furnace's upper portion. In addition, the furnace is designed with a refractory lining push-out device to allow lining removal in 10 min.

Select No. 035 at www.moderncasting.com/info

Cime introduced its model CAP coreless automatic pressure pour furnace. The system has an eliptical coil designed to improve duct heating and overall electrical efficiency, with the ducts inside the furnace's magnetic field for continuous heating. This allows the pouring cycle to begin at any time without slag adhesion due to freezing.

Select No. 031 at www.moderncasting.com/info

Nonferrous Melting & Pouring

Morganite Crucible highlighted its King-Size electric resistance bale out furnace in its GIFA exhibit. Designed to be the ideal metal supply solution for large castings, the HE furnace is constructed from efficient, low thermal mass lining materials and provides optimum economy in energy costs. The insulation allows for optimum melting performance at high power efficiencies, consistent with long element panel life. Radiation losses are minimized by the use of well-insulated covers that can be sealed when no baling out or filling is required.

Among some of the key features:

* accurate metal temperature control, minimizing oxide formation and allowing temperature adjustments;

* no metal segregation or corundum formation within the crucible;

* crucible baffle fitted to ensure continuous dross free metal takeout;

* shallow depth crucible--easy emptying for alloy change;

* superior insulation providing low cost energy usage during non-production times;

* rapid temperature recovery following cold metal additions;

* crucible can be offered incorporating a fine filter assembly;

* spilled metal containers under the furnace.

In addition, the firm highlighted its Hot-Rod silicon carbide thermo-couple sheaths, which provide increased service life as well as improved accuracy and response.

Select No. 072 at www.moderncasting.com/info

Meltech exhibited its Stotek Dosotherm Furnace. This melt holding and pouring system utilizes a two chamber, crucible style holding furnace with reverbatory style modular elements fitted with the firm's pouring pump. The pump uses vacuum technology to draw aluminum from the holding chamber into the mold. An electrode senses that the pump is full and the vacuum is released, allowing any excess aluminum in the pump to flow back into the holding chamber. This ensures that the starting level always is constant. This system's pump uses low air volume therefore making the use of an inert gas such as argon very economical.

Select No. 069 at www.moderncasting.com/info

Among the many benefits to the nonferrous melting industry delivered by Metaullics, the firm showcased its new Tensor Technology for liquid metal pumps that promotes lower maintenance costs and longer pump life. The tensor technology allows new post designs, eliminating wet cement joints during pump construction and rebuilding and upgrading the bearings to resist molten metal attack. This reduces drying time, saving up to 20 hr of lost service time. The technology is available for specification on circulation, transfer and gas injection pumps.

Select No. 070 at www.moderncasting.com/info

Vesuvius Group showcased its new non-wetting, low-cement castable called Aluguard HS 85 that is designed for the high abrasion areas of aluminum foundries. Resistant to thermal shock and mechanical abrasion, this material is designed for charging and pouring areas.

Select No. 095 at www.moderncasting.com/info

Pechiney Aluminum Engineering displayed its Jetcleaner inline trough degassing system that ensures the even dispersion of small bubbles in an aluminum melt by atomizing jets of inert gas using static nozzles. The system's efficiency is comparable to the performance of traditional degassing using rotating nozzles. The treatment capacity is 30 ton/hr.

Select No. 078 at www.moderncasting.com/info

For nonferrous melting and pouring, Foseco focused on its Insural technology insulating refractory material for aluminum and zinc (available as a paste and preformed shapes), Alspek NA electromechanical sensor for the direct measurement of sodium in aluminum alloys and Alspek H electromechanical sensor for the measurement of hydrogen in aluminum alloys. Both the sensors are portable and offer continuous displays of measurement.

Select No. 098 at www.moderncasting.com/info

Gudel displayed its Robospeed modular system of gantries for high-speed applications including pouring. The systems have high-precision guideways with hardened and ground helical form racks. These systems can handle payloads up to 125 kg and have PC-based PLC controls.

Select No. 043 at www.moderncasting.com/info

Striko Dynarad showcased its holding and pouring systems for aluminum diecasting, permanent mold and sand foundries. The newly developed system for green sand foundries allows for the low-pressure pouring of aluminum green sand molds on high-production vertically parted molds. With bottom-pouring of the mold (and a plug used to block the sprue to prevent back flow of the molten aluminum prior to solidification), reduced turbulence is achieved for higher-quality castings. With the pouring system, metal temperature can be held between [+ or -] 2C with reliable pouring accuracy of [+ or -] 2%.

Select No. 088 at www.moderncasting.com/info

Nippon Light Metal introduced the Shizunami degassing and cleaning system for aluminum that uses gas injection through an impeller with a special two-way rotation. This method reduces the turbulence at the metal surface and minimizes the immersion of oxides in the melt. Reduced levels of consumables also are used due to the smaller number of rotations by the impeller.

Select No. 076 at www.moderncasting.com/info

Cleaning, Finishing & Inspection

At its GIFA exhibit, Vulcan Engineering debuted the Fox-All automated casting finishing system designed for job shop foundries. One of the systems on display at GIFA will be installed in Babs Foundry, Norton, Massachusetts, for finishing brass castings.

The system on display featured turntables on both sides for two sets of tooling. The unit features six-axis robotic cleaning and requires only the manual loading of castings. The system can be used for all ferrous and nonferrous metals, with only the simple changing of the abrasive. The 424 model handles castings up to 100 lb and the 636 model can handle castings up to 200 lb. The system, which comes with 12 tools, also features a barcode system to scan tooling, and is offered with a Tru-teach offline programming system for quick and easy programming. Also at the event, Vulcan announced that it would be installing a retrofitted Truflo lost foam system at BMW Foundry, Munich, Germany.

Select No. 096 at www.moderncasting.com/info

Didion focused on its MK5 media drum, including several new features for better uptime and overall performance:

* the spring-loaded chain tensioning system makes maintenance far easier while also extending the life of the drivechain, drum and drive sprockets and reducing shock loading on the reducerp;

* an external sand screen improves screening and conditioning and is easily replaceable with segmented screen panels;

* the new style endtrucks feature extra heavy-duty pillow block bearings with replaceable bearing inserts to allow for faster and easier changeout;

* the heavy-duty interlocking wear liners are 50% thicker and 56% wider for more open area. With fewer rows per machine, foundries will require less service time and longer liner life;

* the tapered media cylinder liners are available specifically for nonferrous and delicate applications in which the castings should be discharged quickly once emerging from the protective media bed.

Select No. 033 at www.moderncasting.com/info

In addition to highlighting its Sand-Lion 3-in-1 Systems that combine casting heat treatment, thermal sand de-bonding and thermal sand reclamation, CEC's GIFA exhibit is focused on a patent-pending technology that combines thermal sand reclamation with shell sand re-coating.

This integrated technology is of interest to metalcasters due to its: energy savings; reduced costs for coated sand purchases and freight; complete environmental control; process control and reduction of foundry sand wastestreams by as much as 95%. For these reasons, CEC officials cite a quick payback on the equipment investment. The firm also is now offering a "sandlease" and "sand-payment" equipment financing program to metalcasters.

Select No. 030 at www.moderncasting.com/info

Italy-based Maus, represented in the U.S. by Reich Companies, showcased its automated robotic casting grinding cells for job shops and high-production foundries. The high-light of the exhibit was the virtual demonstration of the offline learning system for the grinding cell. This feature allows foundries to program the machine in a manner similar to that of a CMM but while the system remains in operation. These grinding systems have dual stations to allow the grinding of two different castings at once. Maus is also providing tooling nests that enable multiple-casting grinding at one time.

Select No. 068 at www.moderncasting.com/info

In connection with Maus, the Austrian firm Throlit showcased its Focur abrasive tools for automatic grinding and machining systems that was developed in cooperation with the Italian firm. These tools have increased wear properties, which reduces machine downtime. Throlit also displayed its Secur ST cut-off wheel that is thin enough to reduce material losses by 20% compared to other wheels. The wheel is offered from 8-12 mm in thickness and from 1000-1600 mm diameters.

Select No. 091 at www.moderncasting.com/info

To help foundries easily and quickly make decisions at inspection, a new X-Cube Compact radioscopic inspection system is now available from Yxlon, According to the firm, it is the result of combining best practice mechanical concepts and software with new, innovative ideas (two patents pending). The X-Cube Compact is a versatile 160 KV radioscopic inspection system for spot tests and inspection of small series of test samples, including light metal castings, steel components and special alloys. The flexibility of the system allows applications as varied as production, incoming inspection, failure analysis or R&D. The integrated Image Enhancement System Vistaplus III offered in the standard version provides fast and easy inspection. The height, weight and size of possible test samples, fast loading/unloading, ease of operation and programming and the proven image enhancement system provide foundry personnel with the tools for fast and correct decisionmaking ability. In addition, a workpiece table, three-jaw chuck and fixing kits are also available for particular inspections. This allows X-rays to pass through the test sample without creating shadows that disturb the results.

Select No. 097 at www.moderncasting.com/info

Pangborn Europe displayed its new continuous blast machine, the model TR. Designed for high-volume processing of automotive castings, the system works in-line and is fully automatic. Typical applications for this new system include brake discs and drams, transmission housings, and cylinder blocks and heads.

Select No. 077 at www.moderncasting.com/info

Reichmann & Sohn showcased its line of automatic grinding and cutting systems, focusing on its Rema systems for high--performance gating system removal. Designed for job shops and high volume work, these systems have abrasive cutting discs running up to speeds of 100 m/ sec. Built in lasers project the cutting line onto the casting while either straight or depressed center wheels perform the cutting.

Select No. 080 at www.moderncasting.com/info

Rosler Group showcased its line of cleaning and finishing solutions including the Roboblaster RROB 350/ 700-4 blast wheel shotblasting system with robot support for deburring, shotblasting and compression blasting of impact sensitive cast components. The maximum length this automatic system can accommodate is 1200 mm with an envelope circle of 600 mm.

Select No. 083 at www.moderncasting.com/info

Fill Technik der Zukunft demonstrated its futuristic looking Swingmaster SM3 decoring system at GIFA. With a vibration amplitude of 32 mm and frequency of 16 Hz, the system has a capacity (including the fixture) of 280 kg. To assist in core removal, the system can rotate up to 270 degrees.

Select No. 038 at www.moderncasting.com/info

Another decoring solution on display was Frolich + Klupfel's technology that utilizes compressed air. While the firm designs systems for handhetd solutions as well as high production operations, the focus of its booth was fully automatic plants with transport systems and programmable controls. The firm stressed that its systems can be designed for jobbing foundries where tooling changeover times must be short because of its clamping operation that supplies the impact energy for decoring.

Select No. 041 at www.moderncasting.com/info

ProService Technology showcased its new range of riser breakers for aluminum called Cutal. Exhibiting from the Clansman Dynamics booth, this hand held shear is individually designed for the customer's casting application using the firm's cutting technology. The technology is actuated by hydraulic power units.

Select No. 079 at www.moderncasting.com/info

Metronor provided demonstrations of its Solo portable coordinate measurement for the inspection of castings, patterns and molds on the shop floor. Using CAD data, the system compares the completed object to the design to ensure dimensional accuracy.

Select No. 071 at www.moderncasting.com/info

The ACRE 280 displayed by Bosello High Technology is an automatic non-destructive testing system that uses turntables and a carousel conveyor to inspect castings in less than two sec. The system's five handling axis are CNC controlled and they can be interpolated.

Select No. 027 at www.moderncasting.com/info

Massin Technologies introduced the new Masdim chipping system with a design that has eliminated all the mechanical parts associated with vibration for reduced maintenance. The technology comes in a horizontal and vertical model and is designed as "plug and play," requiring only compressed air and electrical power to start up.

Select No. 066 at www.moderncasting.com/info

Automation & Casting Handling

General Kinematics' GIFA exhibit focused on new and unique applications of vibratory technology for foundries. Among the new product offering was an innovative 90-degree two-way feeder, featuring an exclusive design that permits bi-directional conveying. Material flow is easily reversed by changing the rotational direction of a single motor. The two-way feeder designs are ideal for numerous foundry applications, including casting sorting, mold dump, blast loading/unloading and shakeout separation of bad heats.

Also on display was a shakeout with a special deck designed specifically for aluminum castings. This deck protects castings from metal-to-metal contact while also reducing noise. Finally, a 10-degree inclined balanced hot sand and casting mold dump conveyor, capable of handling 500 molds/ hr, is shown within the exhibit. This dynamically balanced conveyor includes a special cast serrated tile deck, electrically heated trough and bolt-on hoods.

Select No. 042 at www.moderncasting.com/info

Kuttner demonstrated a new robot application that integrates a camera with a robot for the automatic sorting of castings. Using an image processing system, the camera scans a pile of castings (either moving or stationary). When the camera recognizes a shape, it communicates to the robot the coordinates for pick up. Newly developed software allows for the tracking and pick up of castings while they are moving, and the robot will place the casting at a preprogrammed location.

Select No. 056 at www.moderncasting.com/info

Henschel's new Andromat AMX manipulator was on display for GIFA attendees. Designed specifically for foundries, the system's continuous 360 degree rotation of the gripper offers infinite versatility in application. The system uses 37 kW of power and has low maintenance bearings that are protected from dirt and moisture. It is ergonomically designed to ensure fluid motion of all components working together as an extension of the operator's arm.

Select No. 045 at www.moderncasting.com/info

Kuka showcased its line of robots designed for the foundry environment. With applications in both melting and cleaning and finishing, these robots are designed in four different payload levels (up to 500 kg) and can be mounted on the floor, on the wall or on a gentry. These robots have extension arms up to 400 mm, and can be designed for linear movement to increase their reach. Two software advancements available with the robot systems are Kuka Sim for the simulation of robot cells for planning and configuration before installation and KR C Office that allows the robots to be programmed even during production.

Select No. 053 at www.moderncasting.com/info

On display at Reis Robotics was the firm's flexible and linear robotic solutions. The flexible solutions can handle payloads up to 80 kg with the learn robots handling up to 550 kg. Both sets of robots have automatic program adaptation and error-tolerant measuring systems. Both also can be programmed via a PC or with a teach pendant.

Select No. 081 at www.moderncasting.com/info

Magaldi introduced its Superbelt conveyor to the foundry audience at GIFA. Made of a steel mesh belt that carries overlapping steel pans, this technology allows all the components of the conveyor to expand in any direction without permanent deformation. This also allows the conveyor to withstand extremely high temperatures. The conveyor has low noise levels and energy consumption and can provide up to a 35 degree incline.

Select No. 063 at www.moderncasting.com/info

While not only utilized in cleaning and finishing applications, Italvibras G. Silingardi (with Martin Engineering Co. as its U.S. representative) showcased its line of electronic vibrators for a variety of foundry applications, including shakeout, core knock-out, reclamation and furnace feeding. Focusing on the MVSI series, this technology uses centrifugal force and has been designed to operate in all environments.

Select No. 050 at www.moderncasting.com/info

Motoman introduced a new line of compact robots for the foundry industry called Motocast. These robots have payload capacity from 6 to 500 kg. Using the Twincast program system, up to three robot's actions can be synchronized by one controller.

Select No. 073 at www.moderncasting.com/info

Modeling, Simulation & Rapid Prototyping 

GIFA is a new product cornerstone for Magma Foundry Technologies. The exhibit featured the introduction of an optimization tool called Magmafrontier, the display of Magma feeder maker and gate calculator, a new Magmaviewer, the display of a new-generation preprocessor as well as the first display of its micro-modeling capabilities for aluminum and magnesium. In addition, the exhibit featured a unique virtual reality "cave," showing attendees the power and depth of casting simulation. Magma officials state that the introduction of optimization tools represent a leap in casting simulation, which has been largely a descriptive tool to date. In the future, the software will be able to support metalcasters and designers with suggestions for optimized parameters gained from physical process simulation.

The exhibit also presented first prototypes for micro-modeling and structure and property prediction of light metals. This fits with the firm's objective of helping designers in making use of process-dependent material properties during the early stages of design.

Select No. 064 at www.moderncasting.com/info

Ashland Casting Solutions and ESI Group announced at GIFA their intent to jointly provide casting simulation soft ware solutions and services to me metalcasting industry. The parties will market ProCAST casting simulation software, a fully integrated design tool in the CAD/CAE chain. ProCAST is a completely modular package that can be adapted to the analysis of any shape casting process, for any alloy.

In addition, Ashland Casting Solutions and Z Corp. announced a new marketing partnership designed to create value and provide integrated solutions to the casting industry. Ashland will distribute Z Corp.'s complete line of 3D Printers and material systems for use in short-run prototype metal casting. ZCast and its complementary material systems were developed to decrease the time and cost associated with prototype metal casting. Using digital data developed from a CAD casting design, the ZCast system uses a 3D printer to build the sand molds and cores with an integrated gating system. These molds and cores then are assembled and ready for pouring. Currently, both aluminum and iron castings have been poured successfully with this process, reducing prototype production from weeks to days.

Select No. 026 at www.moderncasting.com/info

Neilsoft demonstrated its DiEdifice casting simulation software specifically designed for diecasting. While the system calculates filling parameters of the casting, it also aids in gating system design as well as ejection and vacuum venting systems (if used) for diecasting. For ejection, the software computes fixed side and moving side catchment area, total ejection load and number and location of ejection pins. For venting, it calculates venting area required and designs vent channels for vacuum venting.

Select No. 075 at www.moderncasting.com/info

UBE Europe showcased its Proficast 3 shot data acquisition and control system for diecasting. This software allows diecasters to record, archive and analyze the data reflected in the production of die castings, including shot stroke and speed and metal pressure. In addition, the software aids in the performance of data analysis, including quality assessments of the metal pressure and shot cylinder speed profile, and definition of the envelope curve. The open client/ server structure of the software provides access to the data at any time.

Select No. 092 at www.moderncasting.com/info