1. Global trends in
foundry technology and
casting production
Dr.-Ing. Gotthard Wolf, German Foundry Association
Farouk Varachia, Metal Casting Technology Station, SA
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2. Content:
> some statistics
> market trends
> basic expectations of our customers
> technical trends
> the South Africa foundry industry tomorrow
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3. Foundry production in the world 2009
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4. Market trends for the foundry industry
> market volume
> global or regional market
> tendencies
> technical trends
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5. Specific consumption of castings
to per 1 Mio. € added value
Quelle: DGV, ifo-institut
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6. Worldwide movement of castings consumption
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7. Shipping costs and container shipping times
9 ct pro kg
Duration 30 Days Europa
USA
10 ct pro kg Indien
Duration: 50 Days 11 ct pro kg
Duration: 65 Days
9ct pro kg
Duration: 25 Days
11 ct pro kg
Duration 30 Days
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8. Global or regional casting market?
Arguments pro and contra Global Regional
Logistic -- ++
(Just in time / Shipping time / Safety of production)
Quality costs - +
Development partnership -- ++
Cultural differences - +
Wages ++ --
Production costs Materials 0 0
Energy 0 0
Forced local content + -
(castings with high valence)
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9. Tendencies
1. The regional casting markets will dominate
2. In medium-term the production will follow the key market
3. The European and American market remains but the economic
growth will be in Asia
4. Following the OEMs, companies build their new automotive foundries
in the emerging markets.
5. We will see a regional casting market but global enterprises
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10. Growing markets for castings until 2015
(Basis 2010)
Germany Europe NAFTA / USA Asia
Automotive ++ 0 (+) 0 ++
Engineering ++ ++ - +
Energy + + + ++
management
Construction - 0 0 ++
industry
Electronics - - - ++
Ship building - 0 - 0
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11. Technical trends
> Enlargement of the added value chain
> Development partner
> Inhouse machining
> Start-optimazation of production
> reaching the Crest-line
> process planning
> Trend towards complex light weight castings
> Complex castings
> Minimization of wall thickness
> multi-material-castings
> Energy and material efficient foundry process
> Low-emission – moulding and core sands
> Avoiding of non added value steps in production
> Heat treatment
> minimizing of fins and fettling
> Automatisation of foundry processes
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12. The portion of the added value of automobile supplier
industry will arise clearly pro-rata and absolut
Production automobiles
(in million pieces)
Supplier and
Service Provider
Quelle: VDA 2004
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13. Enlargement of added value chain
Casting production
Development performance Enlargement of in-house
component design production depth
design-/component calculation - machining
- assembly of modules
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14. Basis expectations of the customer
to the development partner:
 Support in component development
abilitiy for data handling
guaranteed component properties and costs at time of quotation
(series production readiness)
process and component optimazation during running serial production
cooperation with service providers (special know-how)
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15. Basics for Function Layout and Design
 Product and Function Know-how
- function of module
- integration of module
- design criterions
- calculation of the ‘component strength‘
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16. Start-optimazation by specific start- and quality
management with all partners of supplier chain
Crest-line
Goal Additional production time
Units = additional costs/
per day loss in turnover
Quelle: VDA 2004 Days of production
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17. Importance of process planning phase
will increase
> Time frame is getting closer
> Standards with regard to the calculatory accurancy
will rise
> Components will be designed closer to the ‘limits‘, so the process frame is
getting closer
> Process control and compliance of assured properties in competition to
alternativ production technics are demanded intensively
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18.  Process planning with traditional tools due to the compexity of pocesses and
demands on the accurancy of the planning are at their limits
 New tool:
Computer aided process-simulation
> of all subprocesses in terms of production planning
> of the total process in terms of sequence planning
and optimazation of the total costs
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19. Complex light weight castings
(e.g. Fluid management housing)
Quelle: Verband der Aluminiumrecycling-Industrie e.V. (VAR)
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20. Minimaziation of wall thickness
(e.g. Crankcase, grey cast iron)
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21. Multi-material castings
(steel sheet / Aluminium casting)
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22. Energy and material efficient foundry processes
Changing the focus from
end-of-the-pipe-technologies
> air cleaning with scrubbers
> dumping of waste material
to
integrated environmental protection
> low grade emission processes
> minimization of process materials
> energy efficiency and CO2-reduction
> low emission products
> reuse of recycled products
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23. Energy and material efficient foundry processes
(Recycling of moulding sand, dust and slag - Inside and Outside the Foundry)
Cement
production
Mining industry
Foundry
road construction
asphalt production
raw materials
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24. Low emission - moulding and core sands
(No Bake Binder, BTX emissions)
Benzol Toluol
7000 30000
6000 25000
5000
20000
Benzol [mg/m²]
Toluol [mg/m³]
4000
15000
3000
10000
2000
5000
1000
0 0
1 2 1
Serien-Furanharz-System Askuran LS-System (Neuentwicklung) Serien-Furanharz-System Askuran LS-System (Neuentwicklung)
Xylol
800
700
600
500
Xylol [mg/m³]
400
300
200
100
0
1
Serien-Furanharz-System Askuran LS-System (Neuentwicklung)
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25. Low emission – moulding and core sands
(Cold box binder, BTX emissions)
0,090
0,080
0,070
0,060
BTX [%]
0,050
0,040
0,030
0,020
0,010
0,000
Coldbox-Biosystem Coldbox-Klassisches Coldbox-Silikatsystem Coldbox-
System Lösungsm ittelfrei
Fe-Bindersystem / Fe-binder system
Benzol / benzene[%] Toluol / toluene [%] Xylol / xylene [%]
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26. Avoiding of non added value steps in production
(e.g. Heat treatment of cast iron)
Energy consumption:
Melting: 550 - 800 kWh/t
Ferritizing/:
Perlitizing 650 - 750 kWh/t
Avoidable by modern process technology
Stress relief No added value!
heat treatment: 350 - 450 kWh/t
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27. Avoiding of non added value steps in production
(Minimizing of fettling by avoiding fins and joint flash)
as cast as cast too!
Quelle:
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28. Automatisation in core shop
Deburring
For automatic deburring with robots brushes or
templates are used.
Remaining burrs are removed
with the help of a string of
pearls, before the core is
put down and brought
to moulding.
[Source: www.robotec.de]
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29. Automatisation in core shop
Automatic coating of cores is at the today's time
state of the art.
[Source: www.robotec.de]
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30. Automatisation – Moulding Plant
The robot cell has three different stations
> Depalletizing of the cores and
turning over the empty core
packages
> Setting cores and filters
> Unpacking and suppling filters
[Source: Giesserei 94 (2007) Nr. 7, Seite 70-72 ]
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31. Main challenges regarding the production
technology in foundries
Expansion of the value added chain by:
- building of an extended development capacity
- integrating machining as well as assembly capacities in the foundries
Trend towards complex lightweight construction castings
- Rise in number of patterns because assembly variants will disappear
- Demand for individual material properties
- Reduction of planning stage and start-up time
- Development of production flexibility and new logistics patterns
Constant refinement of production technology and production control to meet the
demands ot these complex circumstances
> High capital asset in automation and mechanical processing
Skills and qualification of staff must grow accordingly
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