GIFA 2007, Part two: showcasing metalcasting's cutting edge: as the final installment of a two-part series, this article looks at melting, cleaning, sand preparation, heat treating, testing and casting process modeling equipment and services highlighted at the world's premier metalcasting event.

A MODERN CASTING Staff Report

Following the review of sand mold and core making, permanent mold and diecasting and robotics equipment published in the July issue of MODERN CASTING, this second part of the series highlights the remaining metalcasting categories touched on at GIFA 2007, June 12-15 in Dusseldorf, Germany. As part of four concurrent international technology trade fairs, GIFA provided the opportunity for companies across the globe to unveil their newest and most innovative developments.

Melt, Melt Quality, Pouring and Refractories

ABP Inductions medium-frequency coreless induction furnace type IFM was featured at GIFA. It is utilized for melting and holding ferrous and nonferrous metals and has a melting capacity of 8 to 35 tons and a connection capacity rated at 3 to 16 MW. The IFM furnace system provides high reliability and availability, high melting rates (30tons/hour), high operational safety and low noise emission.

The Vertiplex Channel Furnace highlighted at the Ajax Tocco Magnethermic booth is designed for holding, duplexing and melting ferrous alloys where a constant supply of metal is required to meet production demands. The Vertiplex can pour and receive metal at the same time. The furnaces feature Jet-Flow channel inductors.

Atherm focused its GIFA efforts on two products, the TH170 and the Supratherm 20 kW. The TH170 is the company's response to liquid aluminum delivery problems. The heater maintains and reheats aluminum in the transport ladle with no carbon dioxide reject and 100% yield with no generation of corundum. The heater is inserted into the ladle and heats the center of the liquid aluminum at a rate of 40 kW up to 41-44.6F (5-7C) per minute.

The Supratherm 20 kW heater allows end users to heat metal in a furnace, crucible or ladle with a minimum bath level.

Can-Eng Furnaces focused its GIFA presence on its newly developed basketless rotary heat treating system for the processing of aluminum intensive automobile components. Features of the new system include reductions in size and energy use and a more compact footprint, all due to the elimination of baskets.

Capital Refractories used GIFA to highlight its recent acquisition of Capital Injection Ceramics, a manufacturer of ceramic cores for the investment casting industry, including cores for some of the largest and most complex vanes and blades for the aerospace industry. Capital Refractories also showcased new products that were developed since the 2003 GIFA, including gas diffusers, which are used in conjunction with its linings and have been found to reduce scrap rates and improve the quality of castings in hundreds of sites worldwide.

The PG Series of electromagnetic pumps highlighted at the CMI Novacast booth transfer molten aluminum, zinc and magnesium in a controlled and non-turbulent manner for low pressure filling of sand, permanent or semi-permanent molds. The pump also can be used as a metering device for filling of molds via gravity.

Condat Lubricants introduced its new Condafond Range lubricants for aluminum, magnesium and zinc alloys. The lubricants are now made of different synthetics and are wax-based, with concentrations ranging from 0.5% to 3%.

This year at GIFA, Contimelt Limited launched its newly developed range of budget-priced induction melting furnaces, which feature rigid steel construction with heavy duty shunts for magnetic screening. Advantages of the new line include simplicity and affordability.

Foseco Metallurgical Inc., one half of the casting Competence Center at GIFA, showcased two new products including VSK Compressor core technology and iron filtration equipment involving Disamatic pattern plates and Kalpur direct pour technology. Compressible Breaker core designs have been developed recently to yield maximum amounts of castings and reduce energy consumption. Demonstrations of the VSK Compressor highlighted improvements in cleaning characteristics, safety and quality.

Foseco also highlighted its Feedex VSK Feeding, which combines direct pour feeder-filter techniques and recent advancements in compressible breaker core designs for maximum casting yields that reduce casting processing and energy consumption. The feeding system has been successful in maintaining the highest quality demanded for safety critical automotive and engineering components and, with optimum feeder location, can eliminate traditional gating techniques to achieve high quality shrinkage-free castings.

Foseco unveiled its third generation of Metal Stream Inoculation with dynamic control, which consists of reproducible and accurate dosing equipment, a digital camera for checking the correct continuous addition of inoculants, a thermal analysis device for checking the iron nucleation site, and a touch screen control unit for monitoring equipment and recording data.

Heinrich Wagner Sinto presented its automatic pouring machines, which allow continuous pouring of gray and ductile iron on all kinds of molding plants within the cycle times. Tilting pouring ladles ensure regulation and quantity of molten iron flow. The stream is controlled by means of optical sensors and cameras, and a programmable regulating system matches the pouring speed to the mold consumption rate. Two standard types of ladle are available--accompanying and stationary--and can be augmented with additional functions as necessary. Tilt ladle in-segment design (i.e. the poured quantity is proportional to the ladle tilt angle) is used on all versions.

Inductotherm introduced its Automated Robotic Melt Shop (ARMS) system, which replaces the furnace operator on the melt deck with a robot that has integrated charging, slag removal, tool handling and remote viewing systems. The robot checks the metal bath grounding, dips the thermo couple lance, slags the furnace, takes metal samples and adds the required trim materials. ARMS can be configured for any size ferrous or nonferrous metalcasting facility.

Kuttner highlighted its metalcasting equipment, such as batching and charging for induction furnaces, green sand preparation, castings/sand separation and cooling, shakeout and dedusting systems. Also showcased were cupola melting products for batching and cooling, gas cleaning, heat recovery, iron and slag treatment and automation.

One of the major concerns in the modern aluminum casting industry is aluminum alloy cleanliness. The requirements for molten metal cleanliness have become extremely stringent. The removal of dissolved hydrogen and unwanted particles from the melt using rotary degassing has become a widely used metalcasting practice. Morgan Molten Metal Systems (MMS) revealed its newly-developed, one-piece silicon carbide rotor and shaft for use in this process. The Morgan MMS rotary degassing rotor has a high resistance to wear in service and has excellent antioxidation properties providing a cost effective consumable for use in metalcasters' degassing processes. Morgan MMS's degassing rotor can be supplied in a range of sizes to suit customers' applications.

Promeos Limited revealed its latest gas burner, the REO, in which burning occurs in a porous, high temperature ceramic as opposed to an open flame. This technique results in a radiating surface area with a homogenous convective heat output, which can be regulated on a scale of one to 20, and reduced carbon dioxide and nitrogen oxide emissions. The porous burner directs heat to the exact required area due to its adjustable shape. The REO can be applied in special industrial thermo processes in which the necessary heat must be directed, precisely measured and capable of operating at the highest power density.

In the first show exhibiting with Metaullics under its name, Pyrotek highlighted a number of products, including the Metaullics Molten Metal Pumps, a line of transfer, circulation and gas injection pumps. Other products included electromagnetic pumping, its Thermbond series of refractories, Sivex ceramic foam filters and the HD-2000 for high performance degassing.

Sorelmetal, an iron-carbon alloy containing low concentrations of manganese, phosphorus and sulfur, was the highlight of the Rio Tinto Iron & Titanium exhibit. With Sorelmetal, ductile iron casters can produce machinable castings up to 23.5 in. (60 cm) thick. The low manganese content of the alloy makes it ideal for the production of crankshafts and gears.

The Shaefer Group presented its interconnected system of aluminum furnaces designed for safe, high-quality, no-labor, non-turbulent molten aluminum transfer. The group has designed, built and installed many of the world's largest automotive-type molten aluminum furnace delivery systems. For example, the company recently installed a 23,405 kg/hour capacity furnace delivering engine head, block and wheel quality aluminum at 1,472F (800C) through 400 ft. (122 m) of heated launder system. Another recently installed system includes 341 ft. (104 m) of heated launder and heated dip well furnaces laid out to consistently deliver aluminum to 20 high pressure die casting machines.

Stotek presented the Alumet Doso crucible melting and dosing furnace available in three models, the 900, 1300 and 1800. The furnace allows automatic dosing of aluminum with the possibility of modifying the metal and changing the metal flow during the dosing cycle. The ergonomic and functional design utilizes Siemens PLC control and yields low maintenance costs. With a power rating of 90-165 kW, the furnaces consume relatively little energy and are fitted with panel heating elements with long duration. Dosing is accurate to +/- 1%.

Stryko Westofen showcased its new type MH 1 StrikoMelter, which is designed for melting rates ranging from 740-2,000 kg/hour. The addition of the melting furnace to the StrikoMelter product family is part of a focused expansion toward smaller units. The MH 1 is a viable option for applications characterized by moderate turn up of material to be melted.

Superior Graphite's Desulco carbon raiser presented at GIFA is designed to improve melting efficiency and the quality of castings from start to finish by providing high carbon purity, low ash and sulfur content, fast dissolution rate, high carbon recovery, high nodule count, chill depth reduction and consistent sizing.

TU Clausthal developed a new high damping Cu-base alloy called Maxidamp at the Clausthal University of Technology. The alloy is currently still under development, but it is easily cast and will be useful when mechanical vibrations or noise are disadvantageous.

Upcast Oy's exhibit showcased recent developments of the Upcastsystem. Features now include increased output from a single-furnace system (from 7,500 tpa to 12,000 tpa) as well as increased output from a double-furnace system (from 30,000 tpa to 40,000 tpa). Also incorporated is an Omega-type inductor which doubles the previously available power range, combined with a significant decrease in specific power consumption.

UCON AG Containersysteme KG (formerly Kuppersbusch Warmetechnik) showcased its newly redesigned KBK burner series with an output range of 3.5 to 18,000 kW. The design can be used in low or high pressure firing systems, and the shape of the flame can be altered to fit the shape of the combustion chamber. Other options include the addition of exhaust vapors, recirculated flue gas and steam to the combustion process, in conjunction with special supplementary modules in order to reduce pollutants.

One of the biggest crucibles in the world was displayed at the Vesuvius booth. The company is working to satisfy the trend to use bigger sizes in electric resistant holding furnaces. Vesuvius also presented its line of transfer launders, which transfer molten metal from a ladle or dosing furnace to the mold. The launders make the transfer without physically or chemically contaminating the metal while reducing the amount of heat loss.

Software and Engineering

The German software company Braun Software & Systeme GmbH exhibited the new version of ERP-SystemPCGuss 2000 configured specifically for metalcasting facilities. Also displayed were case studies featuring in detail an optimized process of castings manufacture, including patternmaking, core production, molding, cutting and trimming, heat treatment, machining and finishing. The ERP system manages work in process activities partially through the use of an integrated calculation/estimation algorithm to show new results of process changes.

ESI Group's simulation tool Procast has been upgraded, and the new version of the program was first unveiled at GIFA. The CAD-based computer software, which allows simulation of complex casting processes through automatic mesh generation, thermal analysis with radiation effects, flow analysis for mold filling, advanced metallurgical options, and fully coupled thermal, flow and stress analysis, provides metalcasters with the capability to test more mold designs in less time. Improvements on the software include:

* porosity prediction by taking into account graphite expansion phenomenon in nodular cast iron;

* reduced time required for meshing models;

* improved parallel processing of mold filling and solidification, allowing the complete casting process to be simulated in hours.

Flow-3D highlighted its General Moving Objects model, which gives engineers accurate predictions of casting processes with moving geometry. This unique capability among CFD codes allows engineers to obtain correct flow rates and pressure gradients for moving ladles and plungers and model centrifugal and squeeze castings, among other things. FLOW-3D can model microporosity and filling defects, such as oxide and air entrainment.

At GIFA, Magma Foundry Technologies presented its latest developments for property modeling of aluminum, cast iron and steel components. Based on microstructure simulation, a quantitative description of both the as-cast and heat treated properties becomes available. Magma's nonferrous module computes microstructures and properties of aluminum alloys, considering the metallurgy, inoculation practice and hydrogen content in the melt. Magma-iron predicts the microstructure of cast iron, from graphite morphology to phase distributions of the matrix. Magma-steel calculates macrosegregation and the microstructure resulting from heat treating in steel castings.

SinterCast co-exhibited with ABP Induction, its technology partner for metalcasting automation. A full version of its System 2000 process control system for compacted graphite iron (CGI) was on display, together with CGI-series production cylinder blocks from Audi, Ford and Hyundai.

The X1 Recall booth presented the company's web-based, self-learning process optimization software. Specifically designed for the metalcasting industry, the software records data to help defect-free casting become a reality. X1 Recall analyzes regular input of process data and allows the user to identify the areas that are having a positive or negative effect on the process. If there are defects or problems, the program automatically suggests corrective actions, but it also reacts and learns from the inputs of staff. The knowledge generated then is captured and saved, providing a historical trail that can be valuable for quality auditing and improvement.

Shakeout, Cleaning & Finishing

ABB's new system, featuring RobotWare Machining FC (Force Control), can reduce overall programming times by up to 80% for robots used to grind castings, improving productivity levels. The system also can reduce programming time for automated deburring, machining and polishing of castings. Lifting one of the last real barriers to productivity improvement in this sector, the new technology removes the bottleneck in the finishing room and increases process efficiency, saving time, raising overall consistency and boosting product quality.

AGTOS provided GIFA attendees with a display highlighting their tumble blast unit for processing a variety of work pieces. Also featured was inventive filter technology with a focus on improved maintenance efficiency.

AscoJet presented its Dry Ice Blasting system, a non-abrasive method of cleaning molds. This method uses compressed air to accelerate dry ice pellets onto the molds at a speed of up to 300 m/second. After impact, the dry ice pellets immediately go back into the atmosphere, leaving behind a clean, dry surface.

The new Delta-Phase Shakeout presented at GIFA by Carrier Vibrating Equipment Inc. is designed to easily adjust to product change, almost eliminating sand carryover and casting damage. The patented Delta-Phase Shakeout uses a variable angle of attack to adjust effectively to each new casting that it encounters. It also can increase output and quality by maximizing sand removal while decreasing maintenance costs and downtime.

Didion International featured its New Mark 5 Series Rotary Media Drum which performs shakeout, sand conditioning, double sand screening, casting cleaning, and casting cooling in one efficient step, so the facility stays much cleaner with less airborne silica dust. By combining these processes metalcasters can save $40-$80/ton. The patented design has the lowest operating cost per ton in the industry worldwide.

The Mark 5 Series streamlines production by delivering cool and clean castings directly to the finishing department. The return sand is blended and conditioned so it is consistent in temperature and moisture content providing better control at a mixer. The sand stays in the system where it belongs. Dust collection is extremely efficient due to the small open area of the dram, and it requires 75% less dust collection than a vibrating shakeout rated at the same capacity. Counterflow air eliminates fugitive dust from escaping, protecting workers from airborne silica dust.

Other system improvements include water quenching directly following the machine to eliminate long cooling conveyors further saving equipment costs, energy, time, and space. For foundries using casting baskets and stage cooling, water quenching following the Rotary Media Drum can streamline production flow and eliminate the bottleneck in the cleaning room.

On display at the General Kinematics booth was the firm's Two-Mass, High-Frequency Vibratory Shakeout and its Vario-Drive shakeout system that was schedule for delivery to Sibelektromotor in Tomsk, Russia. The vibratory shakeout boosts casting throughput by compensating for varying load conditions, assuring full, non-dampening performance. These systems can handle up to 100,000 lbs. and are driven with sealed vibratory motors, eliminating the need for v-belts, pivoted motor bases, couplings and large bearings. The Vario-Drive shakeout system (which is not available in the U.S. or Canada) allows users to adjust casting retention time with the push of a button. In addition, the systems long-lasting components and heavy-duty construction offer extended uptime and low maintenance operation.

Also on display were three new models in the Ducta-Series of rotary drums--Ducta-Sprue, a sprue mill, Ducta-Screen, a rotary shakeout, and Ducta-Clean, a rotary media drum. Ducta-Sprue removes sand from sprees and gates, then collects and conveys it away for recycling while crushing mold and core lumps for higher reclamation rates. Ducta-Screen processes molds to separate and remove sand from castings. Sand exits the drum onto a vibratory conveyor, removing hot sand from the rotating body. Ducta-Clean offers cleaner castings and reduced maintenance by rubbing castings with media to remove tramp sand while separating sprue and gates from castings.

The IceTech Combi presented at GIFA combines dry ice pellet production and dry ice blasting. The new machine blends several units and functions, including a pelletizer unit, a dry ice blasting unit, a distribution system with connections for up to 10 blasting guns, and possible integration in plant control units and automation processes.

L. Janke had on display its casting grinding cells based on hexapod robots (six-footers). Specifically, the firm was showcasing its Robot Trim 200 cell for cleaning iron components. Well established in flight simulator automation, hexapod robots help to unlock new areas of robot application because of their flexibility. Now these automated finishing cells can more cost-effectively perform small and medium runs, castings of several meters in length and different materials.

Magaldi Group focused its GIFA efforts on the steel pan conveyor called the Magaldi Superbelt, which has two new versions. Both the PR type and the PRZ type are designed to improve working conditions during the operations of de-gating and sorting due to the flat surface of the belt. A Magaldi Superbelt PRZ type recently has been installed in a metalcasting facility in Dabrowa Gornicza, Poland.

Maus displayed a SAM 300 grinding machine, the smallest of its wide range of cutting and grinding machines (from 2.2 to 11,023 lbs. [1 to 5,000 kg] of part weight that can be grinded). The SAM 300, which performs riser cutting and grinding, can be fitted with parts from 2.2 to 44.1 lbs. (1 to 20 kg) of weight, including fixtures. It can be equipped with up to four tools and features constant grinding quality by laser and diamond tools and an average cycle time of 30 seconds.

In addition to its deburring centers for small to medium-sized pieces, Mossner's Deburring and Cutting Center 1200 for medium to large-sized pieces was showcased at the GIFA exhibit. The machine is standardized, automated and compact and can perform rough machining, as well as deburring and cutting. The center is fitted with a hanging robot and is compatible with various machining facilities, allowing cutting, milling, grinding, measuring and recognizing. New machining processes can be defined and started within a short time, the center is easily integrated into existing product lines and both automatic and manual loading and unloading are possible. The center is delivered as a complete unit and can be put into operation immediately.

Sermas Industrie focused its GIFA presence on new band saws and heat cutting solutions. The band saws have a self-adaptive infeed that produces more efficient sawing and increases blade longevity by adjusting the infeed speed to blade motor torque. When a blade begins to wear out, the increase in force is compensated for by a decrease in infeed speed.

Danish Staring Maskinfabrik unveiled its newly developed vibrating table. The main feature of the table is that it uses magnets to fasten molds rather than clamps, bolts or screws. The table can be produced in a variety of shapes and sizes.

In addition to its lost foam system engineering, Vulcan Engineering displayed its Fox-all 636 automated casting finishing cell. The system on display at the GIFA was sold to Newby Foundries, West Midlands, England. Its dimensions measure 187 x 94 x 116 in. (4.75 x 2.4 x 2.9 m) with a work envelope of 36 x 15 in. (91.44x38.1 cm). It can handle ferrous and nonferrous castings to 200 lb. (90.7 kg) with a motorized system that operates up to 40 hp. The robot provides 6-axis flexibility for casting cleaning, and the system can be programmed both on and off line with Vulcan's Tru-Teach software package.

Featuring six themed areas, the highlight of the Wheelabrator exhibit was the launch of the new generation Wheelabrator TITAN turbines, a new blast wheel that can be adapted to fit virtually any wheel blast machine. This versatile turbine was designed to enhance performance, reduce maintenance time, cut production cost and improve efficiency by up to 30%.

Heat Treating

BSN presented its first complete solution for heat treatment of aluminium alloy. Major features of the system include possible integration of furnace equipment into inline-processes, automatic loading and unloading of parts, short cycle times and heating different parts simultaneously. Spacious rotary heat furnaces with several tiers have an 80-part capacity for hardening, solution heat treatment, quenching and artificial ageing of aluminium parts, such as engine blocks and crankcases.

Isolor, presented at the Carbone Lorraine booth, is a flexible or rigid insulation material for heat treating furnaces and a patented product designed for long duration in extreme temperature and vacuum environments. It is a sandwich material with inside layers made from flexible graphite and a core with low density graphite foam. The foam allows lower thermal conductivity at temperatures above 1,832F (1,000C). Outside layers allow high resistance to chemical reaction and low particle emission.

CEC showcased its CleanCast heat treating process, which utilizes high pressure, heated air to rapidly heat and thermally de-core castings. This process, in combination with a patented new procedure that allows castings to be loaded into the furnace directly after mold filling, results in substantial operational cost savings, and because of the CleanCast compact design, the system can be installed adjacent to existing casting equipment providing for a complete close proximity cell system.

Hofmann Warmetechnick provided GIFA attendees with an exhibit spotlighting its new facility for the complete heat treatment process, which includes the quenching and ageing of cylinder heads used in the automobile industry. The quenching process can be completed in less than five minutes because of the innovative air preparation and guiding system that can cool the metal from 986 to 356F (530 to 180C).

Sand Preparation & Testing

Carbo Ceramics exhibited its Carbo Accucast media, claiming superior physical and thermal properties to traditional molding media to provide increased media life, casting accuracy and reduced production costs. Manufactured from readily available raw materials, these products provide stable, consistent performance and availability and have proven an ideal replacement for silica, zircon and other specialty sands.

Foseco Metallurgical Inc. also highlighted its recently expanded range of high-productivity and environmentally friendly core binders to include a new generation of PUCB binder. The binders are safer for both people and the environment because they no longer contain aromatic solvents. Due to their high reactivity, the binders can be hardened with low volumes of amine catalyst. The application of the binders has proven successful in the production of complex cores for castings requiring mechanical engineering and automotive end users in both the ferrous and nonferrous sectors.

HA International presented the Cordis inorganic binder system, which contributes to a smoke- and odor-free casting process. Thanks to the inorganic components of the binder, no residues in the form of condensate develop during its use. This ensures increased productivity and reduces a metalcaster's environmental footprint. The binders reduce gas defects in castings and emissions during coremaking. Permanent molds that are used with cores made with the binder do not need to be cleaned several times per shift, as is otherwise customary.

In addition to displaying its full line of nobake molding systems, sand treatment, core production, casting finishing and specialty equipment, IMF s.r.l, featured its 100 tons/hour continuous mixer. These high-speed continuous mixers with single or articulated arm and variable height discharge for all nobake processes also feature binder flow control and sand heating control systems.

At GIFA, Klein highlighted its core sand preparation systems, which combine an efficient mixing process, integrated self-cleaning system and highly abrasion resistant materials. Statormix mixers are equipped with batch hoppers and metering devices for sand, binders and additives, as well as a control system, automatic recipe selection and screen monitoring system. Existing Klein vibrating mixers can be retrofitted with a Statormix 22 to reach the latest standard.

Kunkel Wagner's integrated-conditioning rotary mixer highlighted at GIFA has a capacity range between 15 and 200 tons/hour and delivers uniform, optimum molding sand quality in various production modes. The batch-type sand mixer almost simultaneously fills the sand mixer with return sand and a controlled water addition, blends rapidly with a high-speed rotor and immediate start of the effective mixing phase, and feeds specified additives.

Shengquan Group Share-Holding Co. Ltd. highlighted its NP Series Phenolic Urethane Nobake Resins, which feature a three-part binder system--phenolic resin, polyisocyanate and a catalyst. The resins deliver high production efficiency, rapid curing, and low strip and pouring time. The ratio of bench life to stripping time is 75%, making the resins viable for mold or core production. The NP Series does not contain sulfur or phosphorous, reducing gas evolution and potential for blowhole and surface defects. Suitable for iron, steel and nonferrous casting, the resins offer good collapsibility for reduced cracking.

Also featured was its SQJ610 CO2 Cured Alkaline Phenolic Resins, which deliver a new process for making sand cores and molds. The nontoxic resins do not need special equipment for mold or coremaking and don't contain nitrogen, sulfur or phosphorous. SQJ610 resins offer three days of bench life once mixed with sand, are suitable with cast iron and steel and improve surface finish.

Wohr Foundry Technology exhibited its Continuous Mixers for cold-setting resin-bonded sands. Available in one to 60 tons/hour capacities, the mixers provide minimal adhesive consumption and short run mixing times. They are available in several styles, including single or double articulated, stationary, suspended or mobile. Sand can be conveyed from external silos or integrated day bunkers into the mixing unit. A device at the sand measuring side regulates the amount of sand and adhesive. The components are finally mixed together with armor-plated mixing paddles. The mixing angle and the distance to the trough unit cover can be adjusted separately.

Testing

Haehne displayed its Strain Gauges Amplifier AME 2 with new filtered voltage output. The rise time of the filter can be adjusted between 50 milliseconds and two seconds with a potentiometer located on the front panel of the amplifier. The technology is useful in web tension measurement and possesses two voltage outputs, Galvanic isolation of power supply and outlets and plug-in terminal blocks for pre-wiring and short circuit protection of power supply.

The CS230 Series from LECO, which is ideal for the smaller, lower-volume laboratory looking for a cost-effective solution to carbon/sulfur determination, was a main focus at its booth. Interchangeable infrared (IR) cell configurations enable carbon-only and sulfur-only models to be easily upgraded to dual configurations. An available Windows software version (DSP software is standard) supports optional automation. Standard features include a powerful 18 MHz, 2.2 kW furnace, automatic leak check, barometric pressure control, a series of system set-ups and checks, and an approved recommended method of analysis.

Germany's Parsytec introduced its all-digital inspection system featuring a new dimension for software-based coil quality review. The company's surface inspection system (SIS) combines detection and classification algorithms for matrix and line scan technologies, as well as Ethernet-based digital cameras and web-based results browsing. Reject, reroute and reassignment decisions all are made possible through the use of Quality Yield Management Software.

The VJT C-Arm Inspection System by VJ Inspection Systems provides flexible quality control imaging to improve casting process verification and product analysis. The system utilizes an image intensifier coupled to a high-resolution, high-bit-depth digital camera for real-time viewing and a programmable computer numeric controller to manage parts positioning. The system tilts up to 30 degrees for detection at obtuse angles and is easily integrated into the production process, even with robotic manufacturing cells.

Permanent Mold

The 3HS Tilt-Pour presented at the CMH Manufacturing booth reduces turbulence, provides shorter cycle times and requires less metal for feeding systems. Significant features of the heavy-duty 3HS Tilt-Pour include low maintenance, open frame on three sides, twin cushioned tilt cylinders, smooth tilting motion and twin ram cylinders. Hydraulic power units also are available.