Leading innovations

Many foundries are challenged by the questions of how they can increase their profitability and continue to deliver high quality in the face of dwindling resources. This is where foundry chemistry makes an important contribution with its innovation capabilities. The field substitutes limited and expensive raw materials with equivalent or better alternatives as well as optimizes the efficiency and emission load of its product solutions. An important research focus of our R&D teams is to increase the efficiency of our products while reducing emissions.

At GIFA Forum and in our GIFA EXPERT TALKS, we present our colleagues' latest developments to master our industry's current challenges.

GIFA EXPERT TALKS

EMISSION COMPONENTS OF PU-COLD-BOX SYSTEMS

Two noticeable effects of Cold Box technology towards environmental concerns, observed during the metal casting process, are fume generation and the accumulation of the condensate which results in future fire hazards in the foundries. ASK Chemicals is proud to present this study focused exclusively on the investigation of the effect of several components of a typical Cold Box binder systems (e.g., solvent package, binder percentage, and binder ratio) towards emission generation. This study may be helpful in controlling the less desirable components in emission from the PUCB binder systems as it provide insights to develop more environment friendly and sustainable binder systems for the future.

Dr. Sritama Kar presents an " Analytical Study of the Components of Polyurethane Cold Box Binder Systems Towards Emission" on June 12, 4 pm  at the GIFA Forum.

FREEDOM OF DESIGN WITH EXACTCAST PADDINGS

Casting process-related changes to the geometries, such as thickening or feed channels, are often undesirable and entail long and hard discussions about the final casting geometry. It is therefore necessary to extend the conventional means of solidification control, such as risers and molds, to meet these requirements better and, above all, more quickly. This can be achieved with freely formable exothermic or insulating molding materials, so-called paddings. Organically bonded paddings are unlimited in their geometry. The design possibilities are roughly the same as for conventional cold box cores. They are applied directly as a shaping part of the surface of the casting. Combining this with the proven mini-riser technology opens up completely new possibilities in terms of output and energy.

Marcus Friederici presents “ New opportunities to optimize overall process costs through innovative feeding technologies ” on June 12, 1 pm at GIFA Forum. 

IMPROVED PROCESS AND QUALITY CONTROL WITH EXACTPORE FILTERS

3D filters are presently being used as a cost-effective productivity enhancement. This presentation provides a description of the filter material, its unique structure, and the advantages of it. EXACTPORE 3D filters offer iron and steel foundries as well as high quality foundry casters new and more efficient filtration options for the highest casting quality. Thanks to their particularly sophisticated and well-thought design, EXACTPORE 3D filters provide the highest structural integrity and thus safety and efficiency in use.

Ulrich Voigt presents “Improved process and quality control through the use of 3D printed filters” on June 13, 10:30 am at GIFA Forum. 

Productivity, quality and efficiency with MIRATEC BD

Key features of the MIRATEC BD series dip coatings are shortest handling and drying times to meet the productivity requirements of brake disc foundries. Thanks to the formulation as well as the precise handling and the high precision of the coating application, casting defects are avoided. An important lever for increasing productivity in series casting is the avoidance of coating residues on and in the casting. By adding special peel-off additives, we have succeeded in formulating a coating that detaches from the surface of the casting without leaving any residue, thereby eliminating the need for time-consuming rework. Thanks to the high material yield of MIRATEC coatings, foundries can produce more cores than before with the usual amount of coating.

MIRATEC series also offer the possibility to reduce formaldehyde emissions as needed.

A new generation of coatings based on synthetic refractories

Our innovative fast-drying coating SOLITEC HI 704 offers numerous advantages for large casting applications, including a zircon-free formulation that makes it independent from the volatile zircon market prices. SOLITEC HI 704 offers a short drying time, and a valuable drying indicator by color change. With the reduction of casting defects due to this coating, costs and energy can be saved. In addition, inventory costs can be reduced and safe workplace limits can be met.
The water-based formulation of the coating lowers application costs while its impressive application and impregnation properties produce high-quality castings. 

Want to know more? Meet us at GIFA 2023, Hall 12, Booth A22 and talk to our expert.
In the meantime, watch our on demand webinar about our zircon-free coatings.

Whatch now!

Replacing molding and auxiliary materials with additives

Sand additives are usually used to prevent casting defects. With its new additives, we go one step further and give our products additional valuable benefits that help optimize total costs of ownership. 
At GIFA 2023, we will present the new sand additive VEINO ULTRA MBM 2, which allows complete or partial elimination of expensive special sands. In addition, the hybrid additive, which consists of 70% inorganic components, impresses with a good casting performance and a lower emission load.
The patented sand additive VEINO ULTRA 2000 offers cold box core shops the possibility to increase productivity thanks to its cleaning effect in the core box. The innovative "cleaning effect” leads to a significant reduction of sand and binder build-up. Production interruptions and the duration of core box cleaning can be significantly reduced. What’s more, the use of release agents is minimized.