New technology, advancements shine at CastExpo '02. (CastExpo '02).

This recap of the technology and process advancements exhibited at CastExpo '02 provides foundrymen with a virtual 'tour' of what was new on the show floor in Kansas City.

The first AFS CastExpo of the new millennium provided a forum for industry suppliers to exhibit their latest and greatest equipment, technology, processes and services to a global metalcasting audience. The 327 exhibitors sharing more than 130,000-sq-ft of floor space provided demonstrations of everything from pouring and molding to massages and magic tricks.

Due to the size of CastExpo and the numerous simultaneous events that, drew the attention of attendees away from the show floor, MODERN CASTING has provided the following sampling of information on new (introduced since 1999) technology and technological advancements found on the show floor. Although this sampling isn't all-inclusive of every new product exhibited in Kansas City, it does provide a glimpse into many of the innovations that may have been missed,

This information also can be found on the MODERN CASTING website at www.moderncasting.com. In addition, further information on these and other new products will be found in future issues of MODERN CASTING in the Product Innovations and Metalcasting Supplies sections.

Melting, Pouring & Heat Treatment

Inductotherm Corp. showcased its diverse product mix with an exhibit theme of "solutions for all metals." In addition to the exhibit of the newly acquired Hi-T.E.Q. product lines (including numerous furnace designs and an electric launder system) was the first-time-exhibited AcuTrak direct electric heat crucible furnace. This aluminum melting/holding furnace combines the advantages of induction and resistance furnaces through an air-cooled induction coil to heat the crucible, Because no water system is required, the unit is reportedly more economical to operate than either system alone. The firm also featured live demonstrations of iron melting as well as the new Flexitune induction furnace and power systems for small capacity melting and precious metal melting. Also featured were the Meltminder 200 PC control and management system and Multi-Trak multiple-output power supplies.

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Morganite Crucible displayed for the first time in the U.S. its Dual-Energy (gas melt-electric hold) Mk IV aluminum crucible furnace. Key features of the unit include six gas and six fully embedded electric panels, which are self-interlocking and easily removed for exchange, a high-efficiency burner, and numerous automated temperature controls. Sizes range from 187-3000 lb.

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Thermtronix exhibited two new "noncrucible" furnaces, available in both electric and gas-fired versions. Available in 900-3000 lb ranges, the gas-fired version uses a dry-hearth charging chamber that captures exhaust energy to preheat and melt the charge. A vertical gate filter assures that only clean and filtered aluminum enters the dip-well area. Degassing operates at the metal entrance of the dip-well. The electric version shares much of the same features and reportedly can hold 1 ton of molten aluminum at 1300F for $11.52/day.

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LMI Selcom exhibited with ABB for the first time at CastExpo. The firm featured its Laserpour automatic pouring control system for high production, vertically parted, flaskless green sand mold lines. The control system features a new SLS9000 Line Laser System (comprised of a Line Laser generator and a Line Laser sensor) that attaches to both sides of the pouring vessel and uses a triangulation method to determine the iron level in the pour cup. The redundant level information this method generates allows for fast and accurate level recognition to ensure efficient pouring.

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ABB displayed its Smart FS medium frequency induction furnace for small to medium-size iron, steel and nonferrous melting. With a melt rate between 880 and 2640 lb/hr, the furnace has an open-cage design for easy installation. In addition, it uses modular power supply components for simpler maintenance and the magnetic yokes of the furnace conform to low magnetic radiation workplace requirements.

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Heat treatment was on the mind at Applied Process, Inc., as the firm exhibited its new heat treatment service to produce carbidic austempered ductile iron. This material is a ductile iron containing carbides that have been either thermally or mechanically induced to undergo austempering to produce an ausferritic matrix with an engineered carbide level. This process is geared toward castings in high wear resistance applications.

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Odermath USA, Inc., exhibited the Rotostop Gearbox for controlled ladle pouring. The gearbox features a self-locking mechanism that locks in both tilting directions and a closed housing to protect the gearbox from external damage. An adaptable tube and flange design fits the gearbox to existing ladles without the need to replace the lifting bale or trunnions. The combination of bronze bearings and wearing sleeves ensures easy rotation and shaft protection, while labyrinth sealings protect the bearings from metal splash or slag penetration. An air motor drive is available for use with larger ladles.

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CMI Novacast exhibited its PG Series Electromagnetic pumps. The semi-submersed pump systems draw molten aluminum, zinc or magnesium from below the bath surface and move it through heated launder tubes into permanent, sand or plaster molds, shot sleeves or tundishes with minimal atmospheric contact. With these pumps, operator handling is minimized and gassing is eliminated.

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Refractories

United Refractories Co. exhibited its UNI-RAM VR-S Dry Vibratable Silica refractories for coreless induction furnaces melting iron. These refractories have a denser, less porous matrix for extended melt campaigns, produce lower airborne silica dust, and provide maximum density with all vibration techniques and installation equipment. This redesigned material incorporates easy flow technology to allow improved flowability in installations using automated equipment. According to the manufacturer, foundries have reported 35% increases in furnace campaign life with this refractory when compared to standard silica vibratables.

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Allied Mineral Products introduced several new products at the show. The EVS electric vibrator system installs dry vibratable products without mechanically deaerating the material. Because it is an electric system, air quality is not a concern. In addition, the firm showcased the new Hargenburger graphite stopper rod line now being offered in the U.S. The line provides a new product alternative for automatic pouring vessels. Also promoted was the Minro-Sil 2001 refractory mix, which was designed to shut down penetration when melting ductile-base iron. According to the firm, the product also has been proven to successfully melt galvanized steel charge in a coreless furnace. The firm also exhibited a new patented technology metallic fiber-reinforced dry vibratable product for combating thermal shock resistance.

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Capital Refractories exhibited its Unibore nozzle system for bottom pour ladles. The two-piece design features a larger opening at the outer section of the nozzle when compared to a standard nozzle. In addition, the inner nozzle uses a tapered design available with a range of bore diameters. The reusable outer nozzle and second inner nozzle are sealed with a fiber gasket. The diameter of the nozzles can be changed by replacing the inner nozzle. This system reduces consumable Al costs, vortexing and drag through a more stable and controllable metal flow and allows flexibility in selecting the correct m bore diameter for specific casting jobs. The firm also introduced to the U.S. its isostatically pressed crucibles. The crucibles are composed of layers of alumina, chrome-alumina, mangesia I, magnesia II, sillimanite, zircon and zirconia. The refractory features a smooth internal surface that reduces potential inclusions and offers consistent material properties throughout the crucible.

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Zircar Refractory Composites, Inc., introduced the Refractory Sheet Cylinder Type RS-201 and RS-202 for use as induction coil liners, induction furnace components and molten metal transport tubes. The cylinders are composed of fiber-reinforced ceramic laminate and retain useful properties to 2300F (1260C). This high-temperature toleration allows the cylinders to retain their strength and utility to levels exceeding those reachable by reinforced plastics or asbestos cement replacements. The cylinders offer moderate thermal conductivity and excellent electrical insulation while undergoing no outgassing upon heating. High alumina content makes them resistant to many environments, including molten aluminum.

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Melt Consumables

Palmer Manufacturing & Supply demonstrated the AlumaFilter continuous metal filtration system for aluminum foundries. The system automatically indexes a continuous belt of filter fabric through which the poured or shot molten metal passes. The system can be used on die, permanent mold and sand casting processes.

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Globe Metallurgical Sales, Inc., exhibited its GLO 75-Bi ductile iron inoculant. Designed exclusively for ductile iron, this bismuth-containing inoculant must be utilized with a proper balance of rare earth elements. When in proper balance, the inoculant will increase nodule count, raise eutectic temperature, suppress carbide formation and reduce the tendency for micro-shrinkage.

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Superior Graphite Co. showcased its new CarbSiC products, which are thermally bonded carbon/silicon carbide particles designed for gray iron charge addition and the pretreatment of ductile iron. Produced thermally, this product consists of a shell of silicon carbide and a core of petroleum coke so that residual sulfur and oxygen are present. The pretreatment product enhances the nucleation of graphite in iron and provides a more uniform nodule distribution.

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Pyrotek showcased its HD-2000 and PHD-50 rotary systems for injecting solid fluxes and refining agents, degassing and metal circulation. The HD-2000 provides automated metal processing for melting and holding furnaces. It is a fixed position system best suitable for a repeated operation with a large furnace. The PHD-50 provides portable metal processing, and is a compact unit best suited for multiple, smaller furnaces.

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Sand Molding Equipment

DISA Industries exhibited the DISA Match 130 for the first time with a unit being delivered to Torrance Casting. Designed for short-run jobbing foundries with varied product mixes, the matchplate molding unit features a vertical blow and squeeze and can produce 160 molds/hr. The firm also displayed its automatic coresetter for the unit, which allows the operator up to 20 sec to place the cores without impacting the cored production rate of 120 molds/hr. Also exhibited was the new generation series of vertically parted green sand units (the 230X on display will be delivered to Metal Technologies, Inc.) which is offering larger plate sizes at rates of up to 420 molds/hr. Active filling technology for Disamatic-produced aluminum also was shown.

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Beardsley & Piper (Simpson Technologies) exhibited its new BSM-2016G2 series Matchblomatic, which is being delivered to Buck Co. The automatic machine, which was designed for high uptime and uniform mold quality, offers productivity levels of up to 180 molds/hr. Rapid pattern change features also make low runs cost-effective.

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Hunter Automated Molding Corp. dry-cycled its new HMC 2024 molding center, designed to offer speed improvements while successfully molding deeper on greater volumes of casting work, Using two sets of flasks with patterns that alternately rotate in and out of separate blow/squeeze and closing/coresetting stations, the machine produces 240 molds/ hr when using two patterns simultaneously, or 160 molds/hr when running one pattem.

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Roberts Sinto Corp. exhibited its ACE Compact tight-flask molding machine for the first time. The unit offers advantages in equipment size, pit height, and sand and energy usage, with reported rates of 150 molds/hr (300 for dual-machine systems). The firm also produced molds on its new enhancement to the FBO flaskless molding line, the FBO IIIS series, which can achieve rates of 170 molds/hr with a wider range of mold sizes. The molding line displayed at the show was purchased by H&H Castings. Also showcased was the new vacuum automatic coresetter for use on the entire FBO line.

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Vulcan Engineering Co. introduced its new Truflo 3V0 automatic mold handling system, which mates with matchplate molding machines to offer a fully integrated automatic molding system. The design (patent-pending) requires no pits and only minimal floor space while allowing pouring at low levels. The unit's minimum motions and simple design provide high molding rates with low maintenance.

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Exhibiting as part of the Italian Pavilion, IMF exhibited the nobake mold closing system being installed at Harrison Steel, which is thought to be the world's largest. In addition to other new technologies in nobake molding, the firm also promoted its automatic mold storage and retrieval systems.

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As a new entrant to the North American molding equipment supply chain, Fritz Hansberg, S.p.A. showcased its custom-built, large flask, three-phase green sand molding systems. Capable of mold sizes of 2000 x 1250 x 500/500 mm and productivity of 200 molds/hr, the system's molding sequence features pre-fill, shoot and squeeze sequences. With 50 installations worldwide, these molding systems profess strict compression force control, minimal sand usage, excellent mold hardness across the entire mold face and the possibility of using different facing and backing sand on each mold. The firm recently installed a custom mold line at the Georg Fischer foundry in Singen, Germany, for the production of ductile iron automotive suspension arms.

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Kurtz discussed the recent development and installation of a low-pressure, closed sand mold casting system for aluminum that it developed for the German Foundry Steinrucken. In this system, sand molds are built outside the casting system and then fed onto conveyors that deliver the molds to a lowpressure pouring station where they are clamped and filled. The system casts molds up to 2 m in length.

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Permanent Mold Equipment

The Italian firm IMR and IMR USA exhibited its C40/S gravity pour permanent mold casting machine for copper-base alloys. Designed as a stand-alone machine or grouped in production cells with up to five other machines, the casting system can accommodate dies up to 450 mm in length. The system allows for front or side pouring and has automatic die rotation for dipping before casting.

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C.P.C. USA displayed its counter-pressure casting machines for high-mechanical property aluminum components. Using rugged four-tie-bar construction with an integrated holding furnace, the casting system uses varying degrees of pressure in the casting chamber and furnace to promote tranquil and controlled mold fill.

These systems are currently in production at the Intermet Stevensville plant for aluminum steering knuckles.

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Foundry Automation presented its aluminum and magnesium low-pressure permanent mold casting systems. Designed as single machine systems or multiple machines working in tandem, the systems utilize holding furnaces from 600-1200 kg and an eight-phase pressurization system for mold fill.

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C.M.H. Manufacturing Co. introduced a new Hall permanent mold casting system--the RT-3 Reverse Tilting Casting Machine. The system design allows the mold to be poured while the parting line is perpendicular to the plant floor. The machine tilts the mold during pouring so that the parting line is parallel to the floor for solidification and casting ejection. This model has a maximum die size of 33 x 20 in.

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WFV and Roperwerk promoted their low-pressure permanent mold casting machines. The technology uses a multiphase injection system for exact regulation of mold fill. The system's furnace capacities are 500, 800 and 1000 kg.

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The Italian firm Borli Impianti exhibited its MK156 low-pressure permanent mold casting machine, The system has a furnace capacity of 1000 kg and a maximum operating pressure of 2 bar.

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Coremaking

Responding to the larger volume purchases of amine catalyst in foundry corerooms, Gaylord Foundry Equipment exhibited its newly introduced NPAD-110 amine catalyst supply system, which has eliminated safety concerns with 110-gal catalyst containers. Featuring built-in safety switches to monitor tank, line and supply pressures, the unit's flow monitoring valve senses increases in nitrogen flow and automatically closes the fail-safe supply valves while initiating visual and audible alarms.

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Hottinger Systems promoted its CB-32-HA pitless coremaking machine, which was installed at the new Gastec foundry in Mexico.

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Ashland Specialty Chemical Co. and Arena-Flow, L.L.C. are collaborating on modeling software to optimize the design of a core blowing machine and corebox, ensuring proper cores and reduced scrap and tool wear. The software allows engineers to visualize the sand-filling pattern, determine the location and sizing of blowtubes and vents, optimize blow parameters, and select the proper arrangement of cores on tooling.

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Vulcan Engineering Co. demonstrated core setting with a robot through the use of a vision system. Finding cores in random locations as they move down a conveyor belt, the system sets the cores into the mold before performing both core and mold inspection simultaneously.

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For jobbing foundries, Palmer Manufacturing & Supply exhibited two new core machines: the Palmer-Davcor CM-CB-Jobber coldbox machine it recently introduced to the U.S., and the CM Series nobake core blower. The coldbox unit is designed for low-to-medium volumes and is available in five sizes that range from 10-90 lb single blows. Its nobake core blower was designed to eliminate peripheral components like gas generators and scrubbers. Cores and molds can be produced with the same machine through the use of a swivel mixer.

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Fritz Hansberg, S.p.A., exhibited its line of high-volume cold and hotbox coremaking systems. Available with shoot chamber capacities from 5-300 L, these systems' standard features include: automatic corebox blowing/spraying, core removal, core definning, and tooling changeover and cleaning/inspection. All corebox systems can be adapted to the required tooling dimensions or for use with existing tooling.

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Laempe + Reich Corp. showcased a new coldbox core production system--the LL Series--as a value solution for jobbing foundries. The features of the 180 cycles/hr system include the ability to use existing coldbox core tooling after a simple conversion; the use of vertical and horizontal tooling for up to six parts; fast tooling changes with a vacuum attachment and computer-stored data; integrated hydraulics and the Laempe GasGenerator; and a completely enclosed production cabin for safety and emissions control. The system has a shooting capacity of 32 lb.

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AHB North America debuted its line of coldbox coremaking systems to North America. Manufactured with shooting volumes from 1-250 liters, the systems can handle coreboxes with up to 5 parting lines. The systems are designed for easy tooling conversion. In addition, the Windows-based, touch-screen control system is comprised mostly of off-the-shelf components, resulting in easy maintenance. Built rugged for jobbing foundry environments, these systems are targeted at smaller operations looking to take the next step in automation.

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Dependable/Redford-Carver promoted its line of coldbox core production systems, including the HV7500 and HV15000. The HV7500 model has a blow capacity of 75 lb and features a dry cycle time of less than 20 sec., while the HV15000 has a blow capacity of 150 lb and offers a dry cycle time of less than 22 sec. Other features of the systems include: the use of both vertically and horizontally parted tooling, fixed or loose; compatibility with all popular coldbox processes; advanced hydraulic systems; continuous clamping from blow to cure; a vacuum tooling mount and other quick change tooling features; and a mandrel or drag shuttle for core removal.

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Mold & Core Consumables

Two new phenolic urethane resin technologies were introduced at the HA International booth, the first U.S. exhibition of the firm since the merger of Borden Chemical and Delta-HA. Betaset 2000 provides a marked improvement in core strength and cure times over previous Betaset resins. This performance improvement is expected to expand the use of the Betaset coldbox process, which uses methyl formate vapor to cure cores. The new biodiesel technology incorporates high boiling point and low-VOC agriculturally-derived esters into phenolic urethane resin chemistry for nobake and coldbox applications. Foundries utilizing this technology can expect lower VOC emissions associated with phenolic urethane coldbox and nobake core/mold production.

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Carbo Ceramics exhibited its Accucast ceramic media products as a replacement for silica and olivine sands. The media has high flowability due to its spherical structure increasing opportunities to produce thin-wall castings. Higher fill and compaction cycle rates are achieved with the media at reduced energy levels. The media possesses a low coefficient of thermal expansion resulting in improved casting dimensional accuracy with reduced levels of expansion-related defects. The media is offered in intermediate and low-density lines and has product sizes ranging from 15-70 AFS GFN.

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Three new mold and core consumables were introduced by Hill and Griffith Co. Vein Away is a sand additive introduced at a 2-5% level to substantially reduce the veining defect found on iron castings. Used with chemically bonded cores and molds, the product reduces gas defects and expansion characteristics without harmful emissions. Slikease 50 green sand release agent is a product of blended oils for use with high-pressure molding machines where an increased number of mold draws per spray application are required. The material can be sprayed using hand held or automatic spraying equipment. A biodegradable version of the release agent, Slikease, also was introduced. This version is formulated from renewable resources and has similar properties to the Slikease 50.

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On display at Foseco was an array of developments in mold consumables including: Styromol lost foam coatings, Rheotec 451 XLC coatings, Hardcote W-100 green sand surface conditioner, Celtex and Sedex iron filters, Steltex steel filters and Reverse-Taper Kalpur direct pour units. Castings utilizing each of the products were showcased for attendees, including cast components from Halberg Guss (Germany), Goulds' Pumps, Golden Castings, Fisher Cast Steel, BMW, Mercedes, Citroen, Wisconsin Aluminum, Thomas Foundry, Ohio Aluminum Foundry, Maco Corp., Mercury Marine, Diversacast Technologies, Citation Foam and Willard Industries.

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At its booth, Hormel Foods Specialty Products Div. discussed the new agreement it has reached with General Motors on the patent for the GMBond sand binder. Under the new agreement, Hormel has a worldwide exclusive license to sell the binder to foundries without the obligation for royalty payments. The protein-based binder is nontoxic and environmentally benign.

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Itochu Ceratech Corp., represented in the U.S. by Enprotech Corp., highlighted Naigai Cerabeads 60, a spherical ceramic molding media. The media has high refractory qualities that make it ideal for facing and core applications. A low thermal expansion percentage prevents the generation of expansion-caused defects and allows the production of castings with complex shapes and high dimensional precision. The spherical shape of the media increases flowability and permeability. Crush resistance eliminates large quantities of dust, which improves working conditions and prevents media loss during reclamation.

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Sand Conditioning & Testing

DISA Industries showed its new computerized particle analyzer for the first time, which sand labs can utilize to rapidly determine numerous sand characteristics, including distribution, grain fineness and surface area. The units provide a complete automated process that uses an optical sensor to photo-optically measure particles as they free-fall through a beam of light. The process provides a direct correlation to test sieving. The firm also displayed its newer generation Dietert 336 electronic permmeter, which requires no liquids or mechanical moving parts and offers improvements in speed, accuracy and reliability.

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Roberts Sinto Corp. unveiled its new MIC-MIE compactibility controller. This end-point controller unit is designed to allow corrective measures in a more real-time basis.

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Palmer Manufacturing & Supply introduced its CAM-Series continuous nobake mixer, which is a low-cost, no-frills version of the M-Series mixer.

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First-time exhibitor Tinker-Omega Manufacturing showed several pieces of nobake equipment. Its Tom-Series high speed continuous mixer featuring dual bottom-hinged chamber access doors is designed for easy maintenance and features A/C pump controls. It also showed its G-series above-floor mechanical sand shakeout/reclamation unit targeted for flexibility in foundry expansion/modernization. The unit features no pits, foundations or bucket elevators. It also showed its TOM pattern tagging system (embedded inside the pattern), which provides instant pattern recognition and automatic selection of individual job variables, including resin levels, mixer run times, cure times and iron oxide additions.

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The Hardey Systems product line was exhibited for the first time as a part of Simpson Technologies Corp. New in the sand preparation arena are updated touch screens on the Hartley controller, which provide a more user-friendly interface for foundry technicians. Also exhibited for the first time was a new lab-sized blower for chemically bonded core sand preparation and testing.

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Kunkel Wagner had on display its new-to-North America WM Rotary Sand Mixer. In this batch mixer, three bottom-wall ploughs rotating in counter-clockwise direction turn over and blend the sand, water and additives. Simultaneously, the sand mix is moved to the upper rotor section operating clockwise to aerate the sand layers for dual mixing action. The system ensures efficient mixing by increasing the moisture content in the sand at the beginning of the process to properly disperse the bentonite and uniformly coat the sand grains.

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Eirich Machines, Inc., promoted the Evactherm vacuum mixer/cooler system to prepare green sand. The system eliminates the need for a separate sand cooler and accessories, and does not require the air supply that conventional evaporative coolers need. Dry ingredients are mixed and measured for moisture content and sand temperature. Based on these measurements and an average of previous batches, water is added in metered stages. The water added to cool return sand is boiled off and the saturated steam generated comes in contact with the sand and clay particles in the mixer. This steam reactivates more bentonite than conventional sand mixing. The mixer/cooler system is available in throughputs from 30-150 tons/hr.

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Fata Aluminum exhibited its Hot-Rec thermal reclamation system for green and chemically bonded sand. System throughput ranges from 1-6 tons/hr for chemically bonded sand and 1-5 tons/hr for green sand.

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The Italian firm Fontec introduced its mullers with capacities from 15-130 tons of sand/hr. Using the firm's bond injection technology, these mullers provide the following benefits: additives are introduced under low pressure directly into the sand mass, reducing mulling cycles; internal dusting and mixer wall buildup are eliminated; and additive consumption is reduced up to 20%.

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Melt Quality & Testing

Spectro Analytical Instruments, Inc., introduced its Spectromax benchtop metal analyzer that features high-resolution, multi-matrix charge coupled device detector technology. The system is designed for diverse applications including charge furnace control, elemental analysis and production quality control. The optical system provides full coverage in the 165-800 nm wavelength range, and operators can utilize the firm's SparkAnalyzer software for single keystroke analysis.

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Panametrics displayed its new 25HP Plus ultrasonic thickness, velocity and time-of-flight gage to measure cast components that are difficult or impossible to measure with standard gages. The measurement of sound velocity enables ductile iron producers to monitor the degree of nodularity in their castings. This gage features a large LCD display to show the selected measurement and live ultrasound waveform. The firm also showcased its Epoch 4 advanced digital ultrasonic flaw detector. This tester uses innovative signal processing features to permit testing of thinner materials and a wave pulsar to optimize penetration in thick or highly attenuating materials.

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Angstrom, Inc., showcased Arun Technology's new Metalscan M2550 and M2560 spectrometers for nonferrous and ferrous sample analysis, respectively. These systems use charge coupled device detectors for analysis, but have a compact size and small footprint to fit on a desktop. These systems can analyze elements from the complete range of metals and alloys and utilize touch-screen controls.

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Heraeus Electro-Nite Co. displayed its Contitherm lite iron autopour temperature system and its DT-260 Datalog handheld digital temperature instrument. The autopour temperature system sensor is placed close to the stopper rod in automated, high-production pouring systems to continuously measure the temperature of the iron as it enters the mold. The sensor lasts up to 30 hr in continuous use. The digital temperature instrument is designed for molten metal, and can store 800 measurements and transfers measurements in a ASCII data string to a PC for analysis.

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Leco Corp. exhibited two new analysis systems--the GDS500A Glow Discharge Optical Emission Spectrometer and the GX-51 Inverted Metallograph from Olympus. The spectrometer features a charge coupled device detector for the bulk analysis of metals and access to the manufacturer's exclusive SmartLine service-modem support. The metallograph is ideal for production, quality control and advanced research applications, and offers objectives ranging from 1.25X to 250X, and reticle sliders that accept grain size, micron marker and intercept methods.

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Worldwide Analytical Systems introduced its Foundry-Master optical emission spectrometer. Using the latest solid-state detectors to cover all wavelengths from 160-800 nm, the system has all spectral lines for all metal types available. Total spectrum availability and pattern recognition software perform automatic optical alignment (spectrum profiling) during the first few seconds of a test. The firm also displayed its new PMI-Master portable spectrometer for on-site testing and sorting of metal.

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Herzog Aluminum Corp. exhibited a new semiautomatic cup wheel grinder for the preparation of ferrous samples. The machine is suited for the preparation of thin or thick, standard or nonstandard shaped samples.

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Software

In collaboration with Xsilogy, Inc., Ashland Specialty Chemical Co. also introduced new software development for real-time, wireless, web-based monitoring of foundry process equipment that will integrate Xsilogy's SkyView online process monitoring navigation tool. The initial software product introduction is for the continuous monitoring of coldbox coremaking scrubber systems. This turnkey solution will include analysis, reporting and alerting for the scrubber system as it operates using integrated industrial sensors, wireless transmitters, secure TCP/IP internet networks and data center applications. The new remote monitoring systems will be available through regular Ashland technical service channels to integrate it with existing foundry processes.

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Magma Foundry Technologies, Inc., showcased the latest updates and advancements to its Magmasoft casting optimization software. Featured were the developments in automatic optimization, simulation of microstructures, prediction of residual stresses (including warping and cracking), and the simulation of volatile organic carbon emissions from chemically bonded sand cores and molds.

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B&L Information Systems exhibited the Odyssey software system, designed to help metalcasters with business control. The system, which operates on Windows-based PC platforms, is available with modules for cost estimating, order processing, purchasing, scheduling, quality, production, inventory, job costing, sales analysis, and shipping and invoicing. Data collected by the system helps foundries to track man-hours and jobs, increasing efficiency and eliminating some administrative work. It produces standard and custom reports and utilizes Import/Export Wizard for data exchange with other applications, including accounting software.

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Flow Science, Inc., demonstrated the latest development, Version 8, of its Flow-3D casting modeling software. This version illustrates the use of sets of blocks--multiblock meshing--in computational gridding instead of a single block. The software allows users to create multiple grids to efficiently dicretize complex flow domains and increase simulation speed and accuracy. The multi-block model offers more flexibility in defining boundary conditions at domain boundaries and the blocks can be nested within other blocks or linked with other blocks at their boundaries.

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Guardian Software Systems introduced the newest feature of its software programs, Image Control Management. This a feature allows step-by-step image viewing of parts or procedures. Digital images can be displayed, and each pops up in its own screen, allowing unlimited images to be related and named in relation to multiple steps of the casting process. This new feature is available in the GFS Professional and GFS Enterprise foundry system modules.

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EKK, Inc., demonstrated its improved semi-solid flow simulation software. The software has the ability to capture chaotic semi-solid flow characteristics through the use of an internal variable model. It provides a more realistic simulation when compared to the uniform power law method commonly used. The software also includes a material thermophysical property database and a graphical user interface.

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For energy optimization, ABB exhibited Optimize IT software for energy system planning, monitoring, controlling and reporting. Specifically, the system's abilities include forecasting electrical power needs; monitoring the energy system for optimized performance, energy billing and efficiency; allotting energy requirements to the appropriate energy sources at minimum cost; and offering planning support through the simulation of energy system operations.

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FlowCast, a flow modeling software system, was exhibited by Finite Solutions, Inc. The software shows how molten metal will flow through the gating system and fill the casting cavity generated by solidification modeling system software. Two options of modeling mold filling are available. Quick simulation makes a few simplifying assumptions to quickly model the liquid metal flow. Full simulation is a full-featured computational fluid dynamics simulation of flow based on solution of the Navier-Stokes equations for fluid flow. The software allows users to view progressive temperature, fluid velocity and fluid pressure during the fill. The system works using 3-D CAD models.

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Environmental, Health & Safety

The Klein DC 80 Dust Conveyor was on display at the ALB Klein Technology Group booth. This unit is sized to handle up to 2 tons/hr of foundry dust collected in baghouses. The system measures only 33.5 in. in overall height, allowing it to fit under most baghouse dust discharge openings. In addition, the company showed the all new POW-R-FLO refractory gun.

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Hi-Vac Corp. displayed its Echo Sweeper, a cleaning machine designed to sweep plant floors and collect the debris for disposal. The system, available in different models with varying broom widths, controls broom pressure and adjusts to dips, bumps and other surface irregularities for efficient cleaning. A side broom drives debris to the center of the unit where the broom and a suction fan transfer the dust into the hopper. High-efficiency filters trap the particles in the hopper to keep stirred-up dust from entering the work environment.

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The Dust Agglomerator Pak from Castec, Inc., is a self-contained unit featuring a dust hopper, live bottom bin and a screw feed. The system controls throughput capacity into the high-speed mixing unit. The dust enters a high speed rotating mixer and water is added to wet the dust. The resulting mixture is uniform and eliminates the dust problems that occur with handling dry fines. The system can mix 100-200 lb/min depending upon the specific weight of the product. It includes a high-pressure gear pump, a feeder with a live bottom, a screw feeder drive and a high-speed mixer drive.

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Kirk & Blum (Ceco Environmental) promoted the Intellipulse device technology used in its PAC baghouse controller. The device integrates pulse jet timing, pressure gauging, leak detection, blower controls and other diagnostic sensors for easy control. The technology it employs minimizes compressed air use, assures constant pressure drop and constant air flow through the process, extends filter life and increases filtering. The system regulates pulse duration and the period between rows on a real-time basis, pulsing filters only the amount needed to maintain the desired pressure.

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Industrial Ventilation, Inc., promoted its ventilation system capabilities. Ventilation system applications include air balancing and testing, creation of positive air flow and pressure, venting fumes and particulate, and providing compensating air to offset exhaust systems. A system also can eliminate air stratification, hot or cold spots and stagnation, create cooler environments and control humidity. Systems are tailor-engineered to specific facilities and include analysis, design, fabrication and installation.

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Cleaning, Finishing & Inspection

Maus, represented in the U.S. by Laempe + Reich, introduced its new automatic grinding unit. The concept, which is available in five different machine sizes, handles grinding, milling, gauging, turning, boring and finishing in one automatic cell. Programming is done offline in a CMM environment and simple welded fixtures are used. Two castings may be loaded at one time, and runs of as little as 50 pieces have proven to be cost effective. A laser verifies each casting as part of the cycle. Recently, Aarrowcast became the first non-captive foundry in North America to install the system.

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Hottinger Systems exhibited its new Disc-Inspector for rapid automated inspection of brake discs. In operation at Fritz Winter in Germany, the system allows the simultaneous inspection of all vanes in a brake disc at a single glance, resulting in a foundry's ability to perform 100% inspection at high-volume rates of production. The firm also demonstrated its automated visual inspection system, which can handle up to eight vision tasks--checking tolerances, depth and location of holes, etc.--within 12 sec on an engine block.

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Vulcan Engineering Co. also exhibited several new products. A Fox compliant cutoff saw for use with a robot was exhibited, which makes it possible to cut with a constant pressure in lieu of a constant feed rate. Cutting rates of up to three times as fast have been documented. The firm also displayed a new casting qualification process. In this system, a robot coupled with a vision system locates the casting, analyzes the areas that require cleaning and then cleans only those areas. In addition, this system qualifies the casting through vision gauging (sorting out rejects).

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For shot blasting, Wheelabrator exhibited its BD EZ-Fit Wheel Technology. This bidirectional wheel offers users the advantage of operating the wheel clockwise and counterclockwise, reducing required replacement parts. Using a direct drive design, the wheel offers both standard and custom-base mounting. Available from 25-100 hp and in 16 and 18 in. sizes with 2250-3600 rpm, the wheel is compatible with a variety of shot media.

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DISA Goff exhibited its DTC-2 batch shot blast machine, which is now manufactured domestically. Featuring a direct-drive wheel, a polygonal shaped open top drum and improved loading/unloading features, the unit offers higher cleaning capacity.

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At Roberts Sinto, the Barinder grinder was exhibited and demonstrated for the first time in North America. Automating robotic part handling with the grinding wheel, this high-speed grinder automates the removal of gates, burrs and parting lines on gray and ductile iron castings, and can be equipped with a mini-grinder for internal surface finishing and hard-to-reach areas. Most castings can be cleaned in single-setup, and one operator can run two machines simultaneously. The system on display at the show was purchased by Badger Iron Works.

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Yxlon International showcased two new casting inspection products. With the new MU231 unit designed specifically for light alloy cast wheels, castings are conveyed directly into the machine for inline X-ray inspection within a 6-sec cycle time. The firm also promoted its MU59 fully automatic X-ray inspection system for serial inspection and 100% defect recognition of castings of various dimensions and weights. This unit features two standard robots that manipulate the castings in the X-ray beam itself for minimum inspection times.

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Kyushu Technometal Co., Ltd., represented in the U.S. by Henschel America, promoted the Hitachi Sprue Runner Removing Machine. The machine removes feeder head gates, sprue runners and other metal sections on castings with a strong impact force caused by discharging compressed air. The impact force is strong enough to remove a riser contact up to 3 in. in size on a ductile iron casting. The machine also features one-push button operation and can remove a feeder head every 5 sec. Compressed air is the machine's only power source--an electric source is not required.

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Pangborn Corp. exhibited its new RIM-LOC Reversible 6 and 8 Vane Wheel for shot blast systems. The wheel's vanes runnerhead, impeller and impeller case are reversible to operate in either a clockwise or counterclockwise fashion reducing stock requirements. The wheel's design holds the vanes in place, eliminating the need for pins or attachments.

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Rimrock Corp. displayed its complete line of robot solutions for foundries including its six-axis industrial robot fitted with programming and end-effectors to manipulate castings and perform cleaning and finishing operations. The robot performs a variety of tasks based on the tools (band and disc saws, high-speed spindles, belt and disc sanders, scraping and chipping tools, and brushes) attached. To allow for greater flexibility, a gripper can be fixed to the end of the robot arm to hold the casting and present it to a variety of tools mounted on a tool tree.

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Mossner, represented in the U.S. by Laempe + Reich, showcased its automatic and semi-automatic casting finishing systems. The semi-automatic systems incorporate band or circular saws for casting cut-off. The automatic CNC-controlled systems can incorporate circular or band sawing as well as milling, drilling or other machining functions and trim presses for deflashing. The automatic systems also can incorporate robotic loading and unloading.

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Newage Testing Instruments, Inc., exhibited two systems for hardness testing--its Production Brinell 7000 Series high-production testing system and HiLight Brinell Scope for viewing specimens. The testing system is designed with an automatic load cycle. The scope has built-in LED illumination that lasts up to 150 hr per battery.

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V.J. Technologies exhibited its Model CY75-2000 & Model CY110-2000 Standard X-Ray Cabinet Inspection Systems. Billed as an affordable inspection system for small parts, these systems measure 96 x 17 x 61 in. and are portable (on casters).

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At its exhibit, Honsa Ergonomic Technologies discussed its newest line of vibration-reduced chipping hammers specifically designed for a midwestern captive automotive foundry. Designed for durability, the hammers were installed to rotate to ease an operator's access to casting areas for chipping.

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Materials Handling

CSI Industrial Systems Corp. showcased The Crusher, a system that takes bulky aluminum, iron and copper-base charge materials (scrap, gating systems, etc.) and crushes it to achieve maximum density for more efficient material handling and melt efficiency. The system can be installed in-line after shakeout or in the scrapyard to be fed directly.

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General Kinematics showcased its Vibra-Spout scrap and charge feeder system for furnaces. This system is designed to relieve bridging of long or irregular commingled materials and reduce spillage at the furnace crucible during scrap loading. The self-relieving, spring-loaded design has an optional 360 degree nosepiece with hinges and springs to impart a small amount of flex to the assembly during vibratory feed. Manual spring toggles provide additional relief if necessary.

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At Henschel America, Inc., foundry personnel were able to operate the firm's new AMX Andromat foundry manipulator through the movement of an engine block casting. This manipulator, featuring a one-hand Master-Slave intelligent control arm, can safely lift loads of 1-8000 lb up to 700 lifts/hr.

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Didion International featured its newest rotary media drum equipped with new style interlocked liners with contoured rifling, cast retention rings, automatic chain tensioning, split bearings with quick change inserts, and a tapered separation chamber for fragile castings. The firm also promoted its Mark V Series Rotary Reclaimer. (The system on display was being shipped to the Mexican Navy.) Improvements in the reclaimer include new serrated tooth interlock liners, automatic recirculation of screen overs, automatic chain tensioner, and a new variable jet burner for drying and reclaiming wet sand.

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Conveyor Dynamics featured its new Bi-Directional Conveyor that operates in both directions at the same time with a single drive. The firm also showcased its extra heavy duty Furnace Charge Conveyor with a Hardox 500 wear liner, counterbalanced and isolated design, and an indexing carriage with urethane wheels. The charge system on display was en rout to IMCO Recycling.

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Carrier Vibrating Equipment, Inc., exhibited the VibraTrol Stroke Controller for regulating vibratory equipment operation. The system measures, displays and adjusts the stroke of vibratory units through sound pulses, which then are analyzed and redirected to produce an output signal that controls the drive speed of the vibratory equipment. This assures proper equipment operation to protect against component damage, particularly in applications with drastic load variations that may require adjustments and special handling. It can also be used for precision control on vibrating feeders and fluid bed processors.

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Martin Engineering promoted the S-Class Conveying System featuring an air-supported belt conveyor. The system fully contains the material load, preventing spillage and escaping dust. A low horsepower fan supports the conveyor up to 600 ft, and curtains at the belt entry control the air flow into the transfer point, minimizing air induction. A spoon-loading chute places materials on the receiving belt with the proper speed and direction, and dust curtains in the stilling zone force dust to settle. The low-friction, air-supported system can save up to 30% of energy costs on a horizontal conveyor. The conveyor is available in 10 ft (3.05 m) sections that allow for modular installation and permit easy future extensions.

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Barden Equipment Sales, Inc./NIAC introduced a new machine designed for crushing ductile iron, gray iron, aluminum and brass scrap down to 35% of its original volume.

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Rapid Prototyping, Pattern & Tooling

The German firm EOS exhibited cores produced with its EOSINT S 700 rapid prototyping system using laser sintering technology. Starting with CAD data, lasers in the prototype system build up the desired part geometries of cores and molds using resin-coated foundry sand. This updated system has two lasers and is able to produce prototypes up to 700 x 380 x 400 mm in size.

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Solidscape introduced the PatternMaster 3-D modeling and patternmaking system. The system uses standard CAD files and a nontoxic thermoplastic build material to create rapid prototyping models suitable for molding and casting. It automatically generates any necessary support for model cavities or overhangs using a dissolvable wax support. The maximum build envelope measures 12 x 6 x 8.5 in. (30.5 x 15.2 x 21.6 cm), and the system can achieve an accuracy of +/-0.001 in./in. across the X, Y and Z dimensions.

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Adolf's Pattern Shop, Inc., introduced DuraTech pour-able pattern material. This plastic offers wear and impact resistance and can outwear steel. The material is machine mixed, poured at 250F and requires curing before use. It also can be glued to itself or any clean surface and molded to metals.

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3D Systems presented a new material product line currently focused on stereolithography materials. The liquid photoreactive material comes in two varieties: general purpose and durable. Both materials can be used for multipurpose models, patterns for investment casting, prototype tooling and form/fit/function testing. AccuDur, the durable material, offers high green strength for greater process latitude, high durability and flexibility and a smooth surface finish. The general purpose option, AccuGen, offers a fast build speed, fine feature resolution and sidewall quality.

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