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Why lost foam

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Description of the Lost Foam Casting process and explanation of what makes the Lost Foam Casting Process preferable to other forms of casting techniques.

Published in: Technology, Business

Why lost foam

  1. 1. WHY LOST FOAM ? Presented by Karel Cermak
  2. 2. 1.CASTING TOLERANCES ARE SMALLER <ul><li>DIMENSION [mm] </li></ul><ul><ul><ul><li>< 25 </li></ul></ul></ul><ul><ul><ul><li>25 to 80 </li></ul></ul></ul><ul><ul><ul><li>80 to 125 </li></ul></ul></ul><ul><ul><ul><li>125 to 175 </li></ul></ul></ul><ul><ul><ul><li>175 to 250 </li></ul></ul></ul><ul><ul><ul><li>> 250 </li></ul></ul></ul><ul><ul><ul><li>Rough guide <175 >175 </li></ul></ul></ul><ul><li>TOLERANCE [+/-mm] </li></ul><ul><ul><ul><li>0.17 </li></ul></ul></ul><ul><ul><ul><li>0.25 </li></ul></ul></ul><ul><ul><ul><li>0.30 </li></ul></ul></ul><ul><ul><ul><li>0.43 </li></ul></ul></ul><ul><ul><ul><li>0.003 per mm </li></ul></ul></ul><ul><ul><ul><li>0.002 per mm </li></ul></ul></ul><ul><ul><ul><li>0.50 </li></ul></ul></ul><ul><ul><ul><li>0.80 </li></ul></ul></ul>
  3. 3. 2.NO CORES ARE REQUIRED <ul><li>LARGE DESIGN FREEDOM </li></ul><ul><li>“ CONTROLLABLE” WALL THICKNESS </li></ul><ul><li>NO CHAPLETS </li></ul><ul><li>NO FINS </li></ul><ul><li>NO MISMATCH </li></ul><ul><li>NO CORE DEFECTS </li></ul><ul><li>NO SAND MIX PROBLEMS </li></ul>
  4. 4. 3.NO PARTING LINES <ul><li>NO DEMOLD DRAFT </li></ul><ul><li>SEVERAL LAYERS POSSIBLE </li></ul><ul><li>DOWNSPRUE AND RISERS CAN BE POSITIONED OPTIMALLY </li></ul><ul><li>NO MISMATCH OR FINS </li></ul>
  5. 5. 4.COMBINATION/ CONSOLIDATION OF PARTS IS POSSIBLE <ul><li>“ GLUE INSTEAD OF FASTENERS” </li></ul><ul><li>DECISIONS IN THE EARLY DESIGN PHASES ENABLE A HIGH ADDED VALUE TO BE ACHIEVED </li></ul>
  6. 6. <ul><li>Al-alloy ( 319 T5 ) </li></ul><ul><li>11.8 kg. </li></ul><ul><li>490 x 330 x 135 </li></ul><ul><li>Semi-Permanent mold and cores </li></ul><ul><li>Lighter </li></ul><ul><li>Reduced machining </li></ul><ul><li>No fettling </li></ul><ul><li>Higher productivity </li></ul><ul><li>Smoother </li></ul><ul><li>Product performance </li></ul><ul><li>Combination. </li></ul><ul><ul><li>Fewer parts </li></ul></ul><ul><ul><ul><li>Less leaks </li></ul></ul></ul><ul><ul><ul><li>Reduced machining </li></ul></ul></ul><ul><ul><ul><li>Fewer fasteners </li></ul></ul></ul><ul><ul><ul><li>Reduced assembly </li></ul></ul></ul><ul><ul><ul><li>Fewer seals </li></ul></ul></ul>CYLINDER HEAD 16 V SATURN / GM 1200 PER DAY IN-HOUSE FOUNDRY so far 1.7 million castings produced compared with:
  7. 7. <ul><li>Al-alloy (319 T5) </li></ul><ul><li>18.2 kg. </li></ul><ul><li>435 x 445 x 280 </li></ul><ul><li>Semi-Permanent mold and cores </li></ul><ul><li>Lighter </li></ul><ul><li>Reduced machining </li></ul><ul><li>Reduced fettling </li></ul><ul><li>Higher productivity </li></ul><ul><li>Smoother </li></ul><ul><li>Product performance </li></ul><ul><li>Combination </li></ul><ul><ul><li>Fewer parts </li></ul></ul><ul><ul><ul><li>Less leaks </li></ul></ul></ul><ul><ul><ul><li>Reduced machining </li></ul></ul></ul><ul><ul><ul><li>Fewer fasteners </li></ul></ul></ul><ul><ul><ul><li>Reduced assembly </li></ul></ul></ul><ul><ul><ul><li>Fewer seals </li></ul></ul></ul><ul><ul><ul><li>Tooling costs </li></ul></ul></ul>ENGINE BLOCK SATURN / GM / 1.9 l / 124 PS 1,200 PER DAY IN-HOUSE FOUNDRY so far 1.7 million castings produced
  8. 8. <ul><li>Al-alloy </li></ul><ul><li>22 kg. </li></ul><ul><li>600 x 300 x 400. </li></ul><ul><li>Die-cast with salt cores </li></ul><ul><li>Lighter </li></ul><ul><li>Reduced machining </li></ul><ul><li>Reduced fettling </li></ul><ul><li>Higher productivity </li></ul><ul><li>Smoother </li></ul><ul><li>Product performance </li></ul><ul><li>Combination </li></ul><ul><ul><li>Fewer parts </li></ul></ul><ul><ul><ul><li>Less leaks </li></ul></ul></ul><ul><ul><ul><li>Reduced machining </li></ul></ul></ul><ul><ul><ul><li>Fewer fasteners </li></ul></ul></ul><ul><ul><ul><li>Reduced assembly </li></ul></ul></ul><ul><ul><ul><li>Fewer seals </li></ul></ul></ul><ul><ul><ul><li>Tooling costs </li></ul></ul></ul>ENGINE BLOCK V6 MERCURY MARINE 300 PER DAY IN-HOUSE FOUNDRY
  9. 9. <ul><li>Al-alloy </li></ul><ul><li>12.4 kg. </li></ul><ul><li>400 x 300 x 350 </li></ul><ul><li>No comparison possible </li></ul><ul><li>Lighter </li></ul><ul><li>Reduced machining </li></ul><ul><li>Reduced fettling </li></ul><ul><li>Higher productivity </li></ul><ul><li>Smoother </li></ul><ul><li>Product performance </li></ul><ul><li>Combination </li></ul><ul><ul><li>Fewer parts </li></ul></ul><ul><ul><ul><li>Less leaks </li></ul></ul></ul><ul><ul><ul><li>Reduced machining </li></ul></ul></ul><ul><ul><ul><li>Fewer fasteners </li></ul></ul></ul><ul><ul><ul><li>Reduced assembly </li></ul></ul></ul><ul><ul><ul><li>Fewer seals </li></ul></ul></ul><ul><ul><ul><li>Tooling costs </li></ul></ul></ul>ENGINE BLOCK V2 KOHLER OHC / 16 PS 350 PER DAY INTERMET
  10. 10. OIL COOLER IVECO 300 PER DAY ALUMINIUM DONGO <ul><li>Al 319. </li></ul><ul><li>2.5 kg. </li></ul><ul><li>250 x 150 x 30 </li></ul><ul><li>Semi-Permanent mold and cores </li></ul><ul><li>Lighter </li></ul><ul><li>Reduced machining </li></ul><ul><li>Less fettling </li></ul><ul><li>Higher productivity </li></ul><ul><li>Product performance </li></ul><ul><li>Combination </li></ul><ul><ul><li>Fewer parts </li></ul></ul><ul><ul><ul><li>Less leaks </li></ul></ul></ul><ul><ul><ul><li>Reduced machining </li></ul></ul></ul><ul><ul><ul><li>Fewer fasteners </li></ul></ul></ul><ul><ul><ul><li>Reduced assembly </li></ul></ul></ul><ul><ul><ul><li>Fewer seals </li></ul></ul></ul>
  11. 11. INTAKE MANIFOLD FIAT 3,500 PER DAY ALUMINIO DONGO <ul><li>Al 319. </li></ul><ul><li>ca. 5 kg. </li></ul><ul><li>280 x 220 x 50 </li></ul><ul><li>Semi-Permanent mold and cores </li></ul><ul><li>Lighter </li></ul><ul><li>Reduced machining </li></ul><ul><li>Less fettling </li></ul><ul><li>Higher productivity </li></ul><ul><li>Product performance </li></ul><ul><li>Combination </li></ul><ul><ul><li>Fewer parts </li></ul></ul><ul><ul><ul><li>Less leaks </li></ul></ul></ul><ul><ul><ul><li>Reduced machining </li></ul></ul></ul><ul><ul><ul><li>Fewer fasteners </li></ul></ul></ul><ul><ul><ul><li>Reduced assembly </li></ul></ul></ul><ul><ul><ul><li>Fewer seals </li></ul></ul></ul>so far 3.5 million castings produced
  12. 12. CYLINDER HEAD FIAT - FIRE ENGINE - PUNTO 1600 PER DAY ALUMINIO DONGO <ul><li>Al 319. </li></ul><ul><li>12 kg. </li></ul><ul><li>370 x 140 x 120 </li></ul><ul><li>Semi-Permanent mold and cores </li></ul><ul><li>Lighter </li></ul><ul><li>Reduced machining </li></ul><ul><li>Less fettling </li></ul><ul><li>Higher productivity </li></ul><ul><li>Smoother </li></ul><ul><li>Product performance </li></ul><ul><li>Combination </li></ul><ul><ul><li>Fewer parts </li></ul></ul><ul><ul><ul><li>Less leaks </li></ul></ul></ul><ul><ul><ul><li>Reduced machining </li></ul></ul></ul><ul><ul><ul><li>Fewer fasteners </li></ul></ul></ul><ul><ul><ul><li>Reduced assembly </li></ul></ul></ul><ul><ul><ul><li>Fewer seals </li></ul></ul></ul><ul><ul><ul><li>Tooling costs </li></ul></ul></ul>
  13. 13. INTAKE MANIFOLD GM-OPEL CORSA 1,200 PER DAY ALUMINIUM DONGO <ul><li>Al- alloy. </li></ul><ul><li>2.45 kg. </li></ul><ul><li>260 x 220 x 190. </li></ul><ul><li>Comparison difficult Sand casting? </li></ul><ul><li>Lighter </li></ul><ul><li>Reduced machining </li></ul><ul><li>Less fettling </li></ul><ul><li>Higher productivity </li></ul><ul><li>Smoother </li></ul><ul><li>Product performance </li></ul><ul><li>Combination </li></ul><ul><ul><li>Fewer parts </li></ul></ul><ul><ul><ul><li>Less leaks </li></ul></ul></ul><ul><ul><ul><li>Reduced machining </li></ul></ul></ul><ul><ul><ul><li>Fewer fasteners </li></ul></ul></ul><ul><ul><ul><li>Reduced assembly </li></ul></ul></ul><ul><ul><ul><li>Fewer seals </li></ul></ul></ul><ul><ul><ul><li>Tooling costs </li></ul></ul></ul>
  14. 14. INTAKE MANIFOLD FORD 2.3 l / 4 Cyl. 1,200 PER DAY INTERMET <ul><li>Al - alloy </li></ul><ul><li>5.2 kg. </li></ul><ul><li>450 x 220 x 85. </li></ul><ul><li>Semi- Permanent mold and cores </li></ul><ul><li>Lighter </li></ul><ul><li>Reduced machining </li></ul><ul><li>Less fettling </li></ul><ul><li>Higher productivity </li></ul><ul><li>Smoother </li></ul><ul><li>Product performance </li></ul><ul><li>Combination </li></ul><ul><ul><li>Fewer parts </li></ul></ul><ul><ul><ul><li>Less leaks </li></ul></ul></ul><ul><ul><ul><li>Reduced machining </li></ul></ul></ul><ul><ul><ul><li>Fewer fasteners </li></ul></ul></ul><ul><ul><ul><li>Reduced assembly </li></ul></ul></ul><ul><ul><ul><li>Fewer seals </li></ul></ul></ul><ul><ul><ul><li>Tooling costs </li></ul></ul></ul>
  15. 15. <ul><li>Al-alloy </li></ul><ul><li>12 kg. </li></ul><ul><li>450 x 420 x 180. </li></ul><ul><li>Sand casting and cores </li></ul><ul><li>Lighter </li></ul><ul><li>Reduced machining </li></ul><ul><li>Less fettling </li></ul><ul><li>Higher productivity </li></ul><ul><li>Smoother </li></ul><ul><li>Product performance </li></ul><ul><li>Combination </li></ul><ul><ul><li>Fewer parts </li></ul></ul><ul><ul><ul><li>Less leaks </li></ul></ul></ul><ul><ul><ul><li>Reduced machining </li></ul></ul></ul><ul><ul><ul><li>Fewer fasteners </li></ul></ul></ul><ul><ul><ul><li>Reduced assembly </li></ul></ul></ul><ul><ul><ul><li>Fewer seals </li></ul></ul></ul><ul><ul><ul><li>Tooling costs </li></ul></ul></ul>GEAR HOUSING SAUER SUNDSTRAND 220 PER DAY WILLARD INDUSTRIES
  16. 16. FMC 250 PER DAY WILLARD INDUSTRIES <ul><li>Al-alloy </li></ul><ul><li>1.04 kg. </li></ul><ul><li>139 x 125 </li></ul><ul><li>Comparison difficult </li></ul><ul><li>Lighter </li></ul><ul><li>Reduced machining </li></ul><ul><li>Less fettling </li></ul><ul><li>Higher productivity </li></ul><ul><li>Smoother </li></ul><ul><li>Product performance </li></ul><ul><li>Combination </li></ul><ul><ul><li>Fewer parts </li></ul></ul><ul><ul><ul><li>Less leaks </li></ul></ul></ul><ul><ul><ul><li>Reduced machining </li></ul></ul></ul><ul><ul><ul><li>Fewer fasteners </li></ul></ul></ul><ul><ul><ul><li>Reduced assembly </li></ul></ul></ul><ul><ul><ul><li>Fewer seals </li></ul></ul></ul><ul><ul><ul><li>Tooling costs </li></ul></ul></ul>CLUSTER HUB
  17. 17. <ul><li>Al-alloy </li></ul><ul><li>0.7 kg. </li></ul><ul><li>90 x 90 x 32. </li></ul><ul><li>Die-cast </li></ul><ul><li>Lighter </li></ul><ul><li>Reduced machining </li></ul><ul><li>Less fettling </li></ul><ul><li>Higher productivity </li></ul><ul><li>Smoother </li></ul><ul><li>Product performance </li></ul><ul><li>Combination </li></ul><ul><ul><li>Fewer parts </li></ul></ul><ul><ul><ul><li>Less leaks </li></ul></ul></ul><ul><ul><ul><li>Reduced machining </li></ul></ul></ul><ul><ul><ul><li>Fewer fasteners </li></ul></ul></ul><ul><ul><ul><li>Reduced assembly </li></ul></ul></ul><ul><ul><ul><li>Fewer seals </li></ul></ul></ul><ul><ul><ul><li>Tooling costs </li></ul></ul></ul>HEATED COVER XXXX 1,000 PER DAY INTERMET
  18. 18. HYDRAULIC HOUSING SAUER SUNDSTRAND 210 PER DAY WILLARD INDUSTRIES <ul><li>Al- alloy </li></ul><ul><li>13 kg. </li></ul><ul><li>350 x 200 x 200. </li></ul><ul><li>Sand casting and cores </li></ul><ul><li>Lighter </li></ul><ul><li>Reduced machining </li></ul><ul><li>Less fettling </li></ul><ul><li>Higher productivity </li></ul><ul><li>Smoother </li></ul><ul><li>Product performance </li></ul><ul><li>Combination </li></ul><ul><ul><li>Fewer parts </li></ul></ul><ul><ul><ul><li>Less leaks </li></ul></ul></ul><ul><ul><ul><li>Reduced machining </li></ul></ul></ul><ul><ul><ul><li>Fewer fasteners </li></ul></ul></ul><ul><ul><ul><li>Reduced assembly </li></ul></ul></ul><ul><ul><ul><li>Fewer seals </li></ul></ul></ul><ul><ul><ul><li>Tooling costs </li></ul></ul></ul>
  19. 19. <ul><li>Al-alloy </li></ul><ul><li>2.8 kg. </li></ul><ul><li>350 150 x 150. </li></ul><ul><li>No comparison possible </li></ul><ul><li>Lighter </li></ul><ul><li>Reduced machining </li></ul><ul><li>Less fettling </li></ul><ul><li>Higher productivity </li></ul><ul><li>Smoother </li></ul><ul><li>Product performance </li></ul><ul><li>Combination </li></ul><ul><ul><li>Fewer parts </li></ul></ul><ul><ul><ul><li>Less leaks </li></ul></ul></ul><ul><ul><ul><li>Reduced machining </li></ul></ul></ul><ul><ul><ul><li>Fewer fasteners </li></ul></ul></ul><ul><ul><ul><li>Reduced assembly </li></ul></ul></ul><ul><ul><ul><li>Fewer seals </li></ul></ul></ul><ul><ul><ul><li>Tooling costs </li></ul></ul></ul>SUCTION PIPE MERCEDES BENZ 200 PER DAY HANDTMANN
  20. 20. ALUMINIUM FAILURES <ul><li>Wrong product choice </li></ul><ul><li>Reluctance to adapt design </li></ul><ul><li>Underestimation of development costs </li></ul><ul><li>Inexperience </li></ul>
  21. 21. <ul><li>Al-alloy </li></ul><ul><li>0.78 kg. </li></ul><ul><li>190 x 170 x 130. </li></ul><ul><li>Semi-Permanent mold and cores </li></ul><ul><li>Lighter </li></ul><ul><li>Reduced machining </li></ul><ul><li>Less fettling </li></ul><ul><li>Higher productivity </li></ul><ul><li>Smoother </li></ul><ul><li>Product performance </li></ul><ul><li>Combination </li></ul><ul><ul><li>Fewer parts </li></ul></ul><ul><ul><ul><li>Less leaks </li></ul></ul></ul><ul><ul><ul><li>Reduced machining </li></ul></ul></ul><ul><ul><ul><li>Fewer fasteners </li></ul></ul></ul><ul><ul><ul><li>Reduced assembly </li></ul></ul></ul><ul><ul><ul><li>Fewer seals </li></ul></ul></ul><ul><ul><ul><li>Tooling costs </li></ul></ul></ul>SUPPORT/CARRIER FLOP 1
  22. 22. <ul><li>Al-alloy </li></ul><ul><li>5.1 kg. </li></ul><ul><li>300 x 300 x 310 </li></ul><ul><li>Semi-Permanent mold and cores </li></ul><ul><li>Lighter </li></ul><ul><li>Reduced machining </li></ul><ul><li>Less fettling </li></ul><ul><li>Higher productivity </li></ul><ul><li>Smoother </li></ul><ul><li>Product performance </li></ul><ul><li>Combination </li></ul><ul><ul><li>Fewer parts </li></ul></ul><ul><ul><ul><li>Less leaks </li></ul></ul></ul><ul><ul><ul><li>Reduced machining </li></ul></ul></ul><ul><ul><ul><li>Fewer fasteners </li></ul></ul></ul><ul><ul><ul><li>Reduced assembly </li></ul></ul></ul><ul><ul><ul><li>Fewer seals </li></ul></ul></ul><ul><ul><ul><li>Tooling costs </li></ul></ul></ul>CYLINDER HEAD FLOP 2
  23. 23. <ul><li>Al-alloy </li></ul><ul><li>1,1 kg. </li></ul><ul><li>110 x 220 </li></ul><ul><li>Welded part </li></ul><ul><li>Lighter </li></ul><ul><li>Reduced machining </li></ul><ul><li>Less fettling </li></ul><ul><li>Higher productivity </li></ul><ul><li>Smoother </li></ul><ul><li>Product performance </li></ul><ul><li>Combination </li></ul><ul><ul><li>Fewer parts </li></ul></ul><ul><ul><ul><li>Less leaks </li></ul></ul></ul><ul><ul><ul><li>Reduced machining </li></ul></ul></ul><ul><ul><ul><li>Fewer fasteners </li></ul></ul></ul><ul><ul><ul><li>Reduced assembly </li></ul></ul></ul><ul><ul><ul><li>Fewer seals </li></ul></ul></ul><ul><ul><ul><li>Tooling costs </li></ul></ul></ul>EXHAUST PIPE FLOP 3
  24. 24. DUCTILE IRON <ul><li>PROs </li></ul><ul><ul><li>No fixed mold process available - very good accuracy </li></ul></ul><ul><ul><li>All parts, like for Al, pourable </li></ul></ul><ul><ul><li>Cleaning room cost savings greater than for Al </li></ul></ul><ul><ul><li>Environmentally cleaner than sand casting processes </li></ul></ul><ul><li>CONs </li></ul><ul><ul><li>The process is sensitive to uncontrolled carbon pickup </li></ul></ul>
  25. 25. <ul><li>GGG 60 ( US 0.7060) </li></ul><ul><li>11.34 kg. </li></ul><ul><li>450 x 200 </li></ul><ul><li>Mask tool & 9 cores </li></ul><ul><li>Lighter </li></ul><ul><li>Reduced machining </li></ul><ul><li>Less fettling </li></ul><ul><li>Higher productivity </li></ul><ul><li>Smoother </li></ul><ul><li>Product performance </li></ul><ul><li>Combination </li></ul><ul><ul><li>Fewer parts </li></ul></ul><ul><ul><ul><li>Less leaks </li></ul></ul></ul><ul><ul><ul><li>Reduced machining </li></ul></ul></ul><ul><ul><ul><li>Fewer fasteners </li></ul></ul></ul><ul><ul><ul><li>Reduced assembly </li></ul></ul></ul><ul><ul><ul><li>Fewer seals </li></ul></ul></ul><ul><ul><ul><li>Tooling costs </li></ul></ul></ul>CRANK SHAFT SATURN / GM 1,200 PER DAY IN-HOUSE FOUNDRY
  26. 26. <ul><li>GGG 50 / 60 </li></ul><ul><li>4.2 kg. </li></ul><ul><li>150 x 140 </li></ul><ul><li>Sand casting with cores </li></ul><ul><li>Lighter </li></ul><ul><li>Reduced machining </li></ul><ul><li>Less fettling </li></ul><ul><li>Higher productivity </li></ul><ul><li>Smoother </li></ul><ul><li>Product performance </li></ul><ul><li>Combination </li></ul><ul><ul><li>Fewer parts </li></ul></ul><ul><ul><ul><li>Less leaks </li></ul></ul></ul><ul><ul><ul><li>Reduced machining </li></ul></ul></ul><ul><ul><ul><li>Fewer fasteners </li></ul></ul></ul><ul><ul><ul><li>Reduced assembly </li></ul></ul></ul><ul><ul><ul><li>Fewer seals </li></ul></ul></ul><ul><ul><ul><li>Tooling costs </li></ul></ul></ul>DIFFERENTIAL CASE SATURN / GM 1,200 PER DAY IN-HOUSE FOUNDRY
  27. 27. <ul><li>GGG 40 </li></ul><ul><li>11.1 kg. </li></ul><ul><li>250 x 200 x 160 </li></ul><ul><li>Sand casting with cores </li></ul><ul><li>Lighter </li></ul><ul><li>Reduced machining </li></ul><ul><li>Reduced fettling </li></ul><ul><li>Higher productivity </li></ul><ul><li>Smoother </li></ul><ul><li>Product performance </li></ul><ul><li>Combination </li></ul><ul><ul><li>Fewer parts </li></ul></ul><ul><ul><ul><li>Less leaks </li></ul></ul></ul><ul><ul><ul><li>Reduced machining </li></ul></ul></ul><ul><ul><ul><li>Fewer fasteners </li></ul></ul></ul><ul><ul><ul><li>Reduced assembly </li></ul></ul></ul><ul><ul><ul><li>Fewer seals </li></ul></ul></ul><ul><ul><ul><li>Tooling costs </li></ul></ul></ul>SPRING HANGER A VOLVO - GM HEAVY TRUCK 240 PER DAY CITATION FOAM CASTING COMPANY
  28. 28. SPRING HANGER B VOLVO - GM HEAVY TRUCK 240 PER DAY CITATION FOAM CASTING COMPANY <ul><li>GGG 40 </li></ul><ul><li>13.4 kg. </li></ul><ul><li>280 x 200 x 160 </li></ul><ul><li>Sand casting with cores </li></ul><ul><li>Lighter </li></ul><ul><li>Reduced machining </li></ul><ul><li>Reduced fettling </li></ul><ul><li>Higher productivity </li></ul><ul><li>Smoother </li></ul><ul><li>Product performance </li></ul><ul><li>Combination </li></ul><ul><ul><li>Fewer parts </li></ul></ul><ul><ul><ul><li>Less leaks </li></ul></ul></ul><ul><ul><ul><li>Reduced machining </li></ul></ul></ul><ul><ul><ul><li>Fewer fasteners </li></ul></ul></ul><ul><ul><ul><li>Reduced assembly </li></ul></ul></ul><ul><ul><ul><li>Fewer seals </li></ul></ul></ul><ul><ul><ul><li>Tooling costs </li></ul></ul></ul>
  29. 29. <ul><li>GGG </li></ul><ul><li>12.3 kg. </li></ul><ul><li>400 x 250 x 160. </li></ul><ul><li>Sand casting with cores </li></ul><ul><li>Lighter </li></ul><ul><li>Reduced machining </li></ul><ul><li>Reduced fettling </li></ul><ul><li>Higher productivity </li></ul><ul><li>Smoother </li></ul><ul><li>Product performance </li></ul><ul><li>Combination </li></ul><ul><ul><li>Fewer parts </li></ul></ul><ul><ul><ul><li>Less leaks </li></ul></ul></ul><ul><ul><ul><li>Reduced machining </li></ul></ul></ul><ul><ul><ul><li>Fewer fasteners </li></ul></ul></ul><ul><ul><ul><li>Reduced assembly </li></ul></ul></ul><ul><ul><ul><li>Fewer seals </li></ul></ul></ul><ul><ul><ul><li>Tooling costs </li></ul></ul></ul>CLAMP GUIDE XXXXX 200 PER DAY CITATION FOAM CASTING COMPANY
  30. 30. <ul><li>GGG 40 </li></ul><ul><li>5.9 kg. </li></ul><ul><li>260 x 230 x 220. </li></ul><ul><li>Sand casting with cores </li></ul><ul><li>Lighter </li></ul><ul><li>Reduced machining </li></ul><ul><li>Reduced fettling </li></ul><ul><li>Higher productivity </li></ul><ul><li>Smoother </li></ul><ul><li>Product performance </li></ul><ul><li>Combination </li></ul><ul><ul><li>Fewer parts </li></ul></ul><ul><ul><ul><li>Less leaks </li></ul></ul></ul><ul><ul><ul><li>Reduced machining </li></ul></ul></ul><ul><ul><ul><li>Fewer fasteners </li></ul></ul></ul><ul><ul><ul><li>Reduced assembly </li></ul></ul></ul><ul><ul><ul><li>Fewer seals </li></ul></ul></ul><ul><ul><ul><li>Tooling costs </li></ul></ul></ul>SUPPORT / CARRIER MERCEDES BENZ, COMPR. MOTOR 120 PER DAY CITATION FOAM CASTING COMPANY
  31. 31. <ul><li>Wrong product choice </li></ul><ul><li>Reluctance to adapt design </li></ul><ul><li>Underestimation of development costs </li></ul><ul><li>Inexperience </li></ul>DUCTILE IRON FAILURES
  32. 32. <ul><li>GGG !!! </li></ul><ul><li>2.0 kg. </li></ul><ul><li>280 x 300 </li></ul><ul><li>Sand casting & 4 cores </li></ul><ul><li>Lighter </li></ul><ul><li>Reduced machining </li></ul><ul><li>Reduced fettling </li></ul><ul><li>Higher productivity </li></ul><ul><li>Smoother </li></ul><ul><li>Product performance </li></ul><ul><li>Combination </li></ul><ul><ul><li>Fewer parts </li></ul></ul><ul><ul><ul><li>Less leaks </li></ul></ul></ul><ul><ul><ul><li>Reduced machining </li></ul></ul></ul><ul><ul><ul><li>Fewer fasteners </li></ul></ul></ul><ul><ul><ul><li>Reduced assembly </li></ul></ul></ul><ul><ul><ul><li>Fewer seals </li></ul></ul></ul><ul><ul><ul><li>Tooling costs </li></ul></ul></ul>STATOR FRAME EXPERIMENT
  33. 33. <ul><li>GGx-highly magnetic </li></ul><ul><li>0.8 kg </li></ul><ul><li>from 80 to 140 mm x 70 </li></ul><ul><li>No comparison possible </li></ul><ul><li>Lighter </li></ul><ul><li>Reduced machining </li></ul><ul><li>Reduced fettling </li></ul><ul><li>Higher productivity </li></ul><ul><li>Smoother </li></ul><ul><li>Product performance </li></ul><ul><li>Combination </li></ul><ul><ul><li>Fewer parts </li></ul></ul><ul><ul><ul><li>Less leaks </li></ul></ul></ul><ul><ul><ul><li>Reduced machining </li></ul></ul></ul><ul><ul><ul><li>Fewer fasteners </li></ul></ul></ul><ul><ul><ul><li>Reduced assembly </li></ul></ul></ul><ul><ul><ul><li>Fewer seals </li></ul></ul></ul><ul><ul><ul><li>Tooling costs </li></ul></ul></ul>EL.-MAGN. CLUTCH FOR CAR A/C - ROTOR EXPERIMENT
  34. 34. GRAY IRON <ul><li>Thinner hard iron surface </li></ul><ul><li>More even solidification </li></ul><ul><ul><li>Reduced stress </li></ul></ul><ul><li>Quicker machining </li></ul><ul><li>Increased machine tool life </li></ul>
  35. 35. <ul><li>GG </li></ul><ul><li>10 - 80 kg </li></ul><ul><li>up to 800 x 1000 </li></ul><ul><li>Sand casting with cores </li></ul><ul><li>Lighter </li></ul><ul><li>Reduced machining </li></ul><ul><li>Reduced fettling </li></ul><ul><li>Higher productivity </li></ul><ul><li>Smoother </li></ul><ul><li>Product performance </li></ul><ul><li>Combination </li></ul><ul><ul><li>Fewer parts </li></ul></ul><ul><ul><ul><li>Less leaks </li></ul></ul></ul><ul><ul><ul><li>Reduced machining </li></ul></ul></ul><ul><ul><ul><li>Fewer fasteners </li></ul></ul></ul><ul><ul><ul><li>Reduced assembly </li></ul></ul></ul><ul><ul><ul><li>Fewer seals </li></ul></ul></ul><ul><ul><ul><li>Tooling costs </li></ul></ul></ul>STATOR FRAME SIEMENS, ABB, BALDOR, DIEZ CA.1000 PER DAY CITATION FOAM, VSETIN
  36. 36. ELECTRIC MOTOR END SHIELD BALDOR 40 PER DAY CITATION FOAMS <ul><li>GG </li></ul><ul><li>12 kg. </li></ul><ul><li>400 x 100 </li></ul><ul><li>Sand casting and cores </li></ul><ul><li>Lighter </li></ul><ul><li>Reduced machining </li></ul><ul><li>Less fettling </li></ul><ul><li>Higher productivity </li></ul><ul><li>Smoother </li></ul><ul><li>Product performance </li></ul><ul><li>Combination </li></ul><ul><ul><li>Fewer parts </li></ul></ul><ul><ul><ul><li>Less leaks </li></ul></ul></ul><ul><ul><ul><li>Reduced machining </li></ul></ul></ul><ul><ul><ul><li>Fewer fasteners </li></ul></ul></ul><ul><ul><ul><li>Reduced assembly </li></ul></ul></ul><ul><ul><ul><li>Fewer seals </li></ul></ul></ul><ul><ul><ul><li>Tooling costs </li></ul></ul></ul>
  37. 37. <ul><li>GG 25. </li></ul><ul><li>4.5 kg. </li></ul><ul><li>360 x 200 x 130. </li></ul><ul><li>Sand casting </li></ul><ul><li>Lighter </li></ul><ul><li>Reduced machining </li></ul><ul><li>Reduced fettling </li></ul><ul><li>Higher productivity </li></ul><ul><li>Smoother </li></ul><ul><li>Product performance </li></ul><ul><li>Combination </li></ul><ul><ul><li>Fewer parts </li></ul></ul><ul><ul><ul><li>Less leaks </li></ul></ul></ul><ul><ul><ul><li>Reduced machining </li></ul></ul></ul><ul><ul><ul><li>Fewer fasteners </li></ul></ul></ul><ul><ul><ul><li>Reduced assembly </li></ul></ul></ul><ul><ul><ul><li>Fewer seals </li></ul></ul></ul><ul><ul><ul><li>Tooling costs </li></ul></ul></ul><ul><ul><li>WATER INLET / COMPONENT BRACKET </li></ul></ul>CUMMINS ENGINE CO 180 PER DAY CITATION FOAM CASTING COMPANY
  38. 38. <ul><li>GG 40 </li></ul><ul><li>22 kg </li></ul><ul><li>600 x 300 x 100. </li></ul><ul><li>Sand casting with cores </li></ul><ul><li>Lighter </li></ul><ul><li>Reduced machining </li></ul><ul><li>Reduced fettling </li></ul><ul><li>Higher productivity </li></ul><ul><li>Smoother </li></ul><ul><li>Product performance </li></ul><ul><li>Combination </li></ul><ul><ul><li>Fewer parts </li></ul></ul><ul><ul><ul><li>Less leaks </li></ul></ul></ul><ul><ul><ul><li>Reduced machining </li></ul></ul></ul><ul><ul><ul><li>Fewer fasteners </li></ul></ul></ul><ul><ul><ul><li>Reduced assembly </li></ul></ul></ul><ul><ul><ul><li>Fewer seals </li></ul></ul></ul><ul><ul><ul><li>Tooling costs </li></ul></ul></ul>EXHAUST MANIFOLD MERCURY INBOARD 120 PER DAY CITATION FOAMS
  39. 39. <ul><li>GG </li></ul><ul><li>10 kg. </li></ul><ul><li>280 x 350 x 220 </li></ul><ul><li>Sand casting with cores </li></ul><ul><li>Lighter </li></ul><ul><li>Reduced machining </li></ul><ul><li>Reduced fettling </li></ul><ul><li>Higher productivity </li></ul><ul><li>Smoother </li></ul><ul><li>Product performance </li></ul><ul><li>Combination </li></ul><ul><ul><li>Fewer parts </li></ul></ul><ul><ul><ul><li>Less leaks </li></ul></ul></ul><ul><ul><ul><li>Reduced machining </li></ul></ul></ul><ul><ul><ul><li>Fewer fasteners </li></ul></ul></ul><ul><ul><ul><li>Reduced assembly </li></ul></ul></ul><ul><ul><ul><li>Fewer seals </li></ul></ul></ul><ul><ul><ul><li>Tooling costs </li></ul></ul></ul>COOLING WATER PUMP DETROIT DIESEL 120 PER DAY CITATION FOAM
  40. 40. <ul><li>GG </li></ul><ul><li>22 kg. </li></ul><ul><li>300 x 400 x 400 </li></ul><ul><li>Sand casting with cores </li></ul><ul><li>Lighter </li></ul><ul><li>Reduced machining </li></ul><ul><li>Reduced fettling </li></ul><ul><li>Higher productivity </li></ul><ul><li>Smoother </li></ul><ul><li>Product performance </li></ul><ul><li>Combination </li></ul><ul><ul><li>Fewer parts </li></ul></ul><ul><ul><ul><li>Less leaks </li></ul></ul></ul><ul><ul><ul><li>Reduced machining </li></ul></ul></ul><ul><ul><ul><li>Fewer fasteners </li></ul></ul></ul><ul><ul><ul><li>Reduced assembly </li></ul></ul></ul><ul><ul><ul><li>Fewer seals </li></ul></ul></ul><ul><ul><ul><li>Tooling costs </li></ul></ul></ul>WATER VALVE BODY M & H NW 150 80 PER DAY CITATION FOAMS
  41. 41. <ul><li>GG </li></ul><ul><li>53 kg. </li></ul><ul><li>550 x 225 x 100. </li></ul><ul><li>Sand casting with cores </li></ul><ul><li>Lighter </li></ul><ul><li>Reduced machining </li></ul><ul><li>Reduced fettling </li></ul><ul><li>Higher productivity </li></ul><ul><li>Smoother </li></ul><ul><li>Product performance </li></ul><ul><li>Combination </li></ul><ul><ul><li>Fewer parts </li></ul></ul><ul><ul><ul><li>Less leaks </li></ul></ul></ul><ul><ul><ul><li>Reduced machining </li></ul></ul></ul><ul><ul><ul><li>Fewer fasteners </li></ul></ul></ul><ul><ul><ul><li>Reduced assembly </li></ul></ul></ul><ul><ul><ul><li>Fewer seals </li></ul></ul></ul><ul><ul><ul><li>Tooling costs </li></ul></ul></ul>CYLINDER HEAD - DIESEL JIN HONG 400 PER DAY IN-HOUSE FOUNDRY
  42. 42. ELECTRICAL MOTOR END SHIELD 80 PER DAY CITATION FOAM <ul><li>GG </li></ul><ul><li>26 kg. </li></ul><ul><li>711 x 120 </li></ul><ul><li>Sand casting with cores </li></ul><ul><li>Lighter </li></ul><ul><li>Reduced machining </li></ul><ul><li>Reduced fettling </li></ul><ul><li>Higher productivity </li></ul><ul><li>Smoother </li></ul><ul><li>Product performance </li></ul><ul><li>Combination </li></ul><ul><ul><li>Fewer parts </li></ul></ul><ul><ul><ul><li>Less leaks </li></ul></ul></ul><ul><ul><ul><li>Reduced machining </li></ul></ul></ul><ul><ul><ul><li>Fewer fasteners </li></ul></ul></ul><ul><ul><ul><li>Reduced assembly </li></ul></ul></ul><ul><ul><ul><li>Fewer seals </li></ul></ul></ul><ul><ul><ul><li>Tooling costs </li></ul></ul></ul>
  43. 43. STEEL CASTINGS <ul><li>High accuracy </li></ul><ul><li>Good surface quality </li></ul><ul><li>Also 3 + mm wall thickness possible </li></ul><ul><li>Reduced machining </li></ul><ul><li>Increased machine tool life </li></ul><ul><li>Reduced cleaning room costs </li></ul><ul><li>Complicated castings possible </li></ul><ul><ul><li>ADVANTAGES </li></ul></ul>LIMITATIONS <ul><li>Alloys with C < 0.15 % </li></ul>
  44. 44. <ul><li>GS - Heat resistant </li></ul><ul><li>1.2 kg. </li></ul><ul><li>180 x 200 x 30. </li></ul><ul><li>Furan Sand </li></ul><ul><li>Lighter </li></ul><ul><li>Reduced machining </li></ul><ul><li>Reduced fettling </li></ul><ul><li>Higher productivity </li></ul><ul><li>Smoother </li></ul><ul><li>Product performance </li></ul><ul><li>Combination </li></ul><ul><ul><li>Fewer parts </li></ul></ul><ul><ul><ul><li>Less leaks </li></ul></ul></ul><ul><ul><ul><li>Reduced machining </li></ul></ul></ul><ul><ul><ul><li>Fewer fasteners </li></ul></ul></ul><ul><ul><ul><li>Reduced assembly </li></ul></ul></ul><ul><ul><ul><li>Fewer seals </li></ul></ul></ul><ul><ul><ul><li>Tooling costs </li></ul></ul></ul>ANCHOR CLUSTER EXPERIMENT
  45. 45. “ DRILL HOOK” PAALS 2,000 PER YEAR GUSSTAHL LIENEN <ul><li>GS 25CrMo 4 </li></ul><ul><li>1.6 kg. </li></ul><ul><li>150 x 100 </li></ul><ul><li>No comparison possible </li></ul><ul><li>Lighter </li></ul><ul><li>Reduced machining </li></ul><ul><li>Reduced fettling </li></ul><ul><li>Higher productivity </li></ul><ul><li>Smoother </li></ul><ul><li>Product performance </li></ul><ul><li>Combination </li></ul><ul><ul><li>Fewer parts </li></ul></ul><ul><ul><ul><li>Less leaks </li></ul></ul></ul><ul><ul><ul><li>Reduced machining </li></ul></ul></ul><ul><ul><ul><li>Fewer fasteners </li></ul></ul></ul><ul><ul><ul><li>Reduced assembly </li></ul></ul></ul><ul><ul><ul><li>Fewer seals </li></ul></ul></ul><ul><ul><ul><li>Tooling costs </li></ul></ul></ul>
  46. 46. WATER COOLED GRATING BODY NOELL 5,000 PER YEAR GUSSTAHL LIENEN <ul><li>GX 40CrNiSi27-4 </li></ul><ul><li>32 kg </li></ul><ul><li>650 x 260 x 100. </li></ul><ul><li>Furan Sand </li></ul><ul><li>Lighter </li></ul><ul><li>Reduced machining </li></ul><ul><li>Reduced fettling </li></ul><ul><li>Higher productivity </li></ul><ul><li>Smoother </li></ul><ul><li>Product performance </li></ul><ul><li>Combination </li></ul><ul><ul><li>Fewer parts </li></ul></ul><ul><ul><ul><li>Less leaks </li></ul></ul></ul><ul><ul><ul><li>Reduced machining </li></ul></ul></ul><ul><ul><ul><li>Fewer fasteners </li></ul></ul></ul><ul><ul><ul><li>Reduced assembly </li></ul></ul></ul><ul><ul><ul><li>Fewer seals </li></ul></ul></ul><ul><ul><ul><li>Tooling costs </li></ul></ul></ul>
  47. 47. CERMAK ENGINEERING PFAHLER STR.21, 65 193 WIESBADEN, TEL.+49 611-1509 9495 E-Mail : kcermak@aol.com PLEASE ENQUIRE ABOUT OUR PRESENTATION PART 2 “ HOW IS LOST FOAM CONTROLLABLE? ”

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