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SinterCast presents new technologies at GIFA world foundry trade fair.

Issued at 2011-06-29



[Düsseldorf, 28 June 2011] - At the GIFA world foundry trade fair, held every four years in Düsseldorf, SinterCast has introduced a suite of new technology advances to extend the functionality and capability of  its Compacted Graphite Iron (CGI) process control technology.  SinterCast's third generation process control system for high volume CGI series production - the fully automated System 3000 - is on display at SinterCast's technology exhibition in Hall 10, Stand G53, incorporating following new features and functionality:
 
Automated Base Treatment Control: as an extension of SinterCast's feedforward measure-and-correct process control technology, the System 3000 now offers automated feedback control of the wirefeeding base treatment operation.  The control logic is based on the automated input of chemistry, temperature and weight for each ladle, plus the actual recovery measured from preceding ladles.  The base treatment control capability is provided by a System 3000 with two wirefeeders, resulting in improved process accuracy and efficiency.
 
Process Database: the System 3000 functionality has been expanded to enable collection of process data from the melting, moulding, pouring and shake-out operations, and from the chemistry and quality control laboratories.  These data are compiled into a single database, together with the SinterCast process control results, to provide improved process control and production traceability.
 
Efficiency Benchmarking: production results are compiled in monthly process efficiency summaries to allow foundry managers to compare their CGI production efficiency to SinterCast's best-in-class customer for key production parameters.  The benchmarking results provide a quantitative basis for implementing process changes and monitoring the continuous improvement of each foundry's CGI production process.
 
Thermocouple Pair Durability: following the System 3000 re-design of the Thermocouple Pair, and a two-year programme of testing and recalibrating used Thermocouple Pairs, SinterCast has increased the preventive replacement limit from 200 cycles to 250 cycles.  The increase improves thermocouple durability and cost efficiency by 25%.
 
Image Analysis: the SinterCast CGI microstructure image analysis routine, adopted by the international ISO 16112 standard for CGI, is now available to SinterCast foundry customers as a separate software programme for use in Image Pro Plus image analysis software.  The image analysis results can be ported to any commercial spreadsheet or database software for process documentation, quality control and traceability.
 
 
In addition to the fully automated System 3000 process control system, the Mini-System 3000 is also on display at the SinterCast stand.  The Mini-System 3000 uses the same sampling technology and thermal analysis software as the fully automated System 3000, but it is based on a simplified hardware platform, with reduced peripheral functionality.  The Mini-System 3000 is available for foundries to support CGI product development and niche volume production.
 
SinterCast has also taken the opportunity of GIFA 2011 to introduce its technology development for the process control of ductile iron.  The ductile iron technology incorporates the core SinterCast thermal analysis principles developed and proven for CGI process control, including a Dewar-type stamped steel sampling device to provide uniform and consistent solidification conditions.  The patented ductile iron sampling device consists of two spherical sampling chambers with different diameters to provide two different solidification rates.  The thermal analysis measurement provides results for microstructure and shrinkage sensitivity that can be used for process control and/or quality control purposes.  The ductile iron technology is introduced at GIFA with the intent to secure field trial commitments beginning during the autumn of 2011.
 
 "The GIFA provides an excellent opportunity for SinterCast to showcase its technology and to meet current and potential customers from around the world" said Dr Steve Dawson, President & CEO, SinterCast.  "We are excited to introduce the extended functionality of our core Compacted Graphite Iron technology and to present our ductile iron thermal analysis development to the market.  We look forward to the next five days in Düsseldorf and to exploring the new opportunities that this unique trade fair can bring." 
 

 


Source: SinterCast



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