JANUARY 2021 foundrymag.

com

2021
Metalcasting
Idea Book
Annual review of innovations IN THIS ISSUE
and trends across the range of How to Select an
process technologies critical to Induction Melter
metalcasting operations.
Advantages of
Collapsible Core Breakers

AM’s Impact on
Investment Casting

A New Approach
to Sand Reclamation

... and much more

Digital Edition Copyright Notice

The content contained in this digital edition (“Digital Material”), as well as its
selection and arrangement, is owned by Endeavor Business Media. and its affiliated
companies, licensors, and suppliers, and is protected by their respective copyright,
trademark and other proprietary rights.

Upon payment of the subscription price, if applicable, you are hereby authorized
to view, download, copy, and print Digital Material solely for your own personal,
non-commercial use, provided that by doing any of the foregoing, you
acknowledge that (i) you do not and will not acquire any ownership rights of any
kind in the Digital Material or any portion thereof, (ii) you must preserve all copy-
right and other proprietary notices included in any downloaded Digital Material,
and (iii) you must comply in all respects with the use restrictions set forth below
and in the Endeavor Business Media Privacy Policy and the Endeavor Business
Media Terms of Use (the “Use Restrictions”), each of which is hereby incorporated
by reference. Any use not in accordance with, and any failure to comply fully with,
the Use Restrictions is expressly prohibited by law, and may result in severe civil
and criminal penalties. Violators will be prosecuted to the maximum possible ex-
tent.

You may not modify, publish, license, transmit (including by way of email, facsimile
or other electronic means), transfer, sell, reproduce (including by copying or
posting on any network computer), create derivative works from, display, store,
or in any way exploit, broadcast, disseminate or distribute, in any format or
media of any kind, any of the Digital Material, in whole or in part, without the
express prior written consent of Endeavor Business Media. To re-
quest content for commercial use or Endeavor Business Media’s ap-
proval of any other restricted activity described above, please contact
the Reprints Department at (877) 652-5295. Without in any way limiting the
foregoing, you may not use spiders, robots, data mining techniques or other
automated techniques to catalog, download or otherwise reproduce, store or
distribute any Digital Material.

NEITHER Endeavor Business Media NOR ANY THIRD PARTY CONTENT

PROVIDER OR THEIR AGENTS SHALL BE LIABLE FOR ANY ACT, DIRECT OR
INDIRECT, INCIDENTAL, SPECIAL OR CONSEQUENTIAL DAMAGES ARISING
OUT OF THE USE OF OR ACCESS TO ANY DIGITAL MATERIAL, AND/OR ANY
INFORMATION CONTAINED THEREIN.

Plant Air Quality and Operating Practices
Shape Core and Moldmaking Results
Monitoring humidity, evaluating compressed-air systems, and assessing binders and catalysts
will help to explain a foundry’s productivity.
Q: Recently, I was promoted from quality engineer
in a small foundry to a new position as molding and
coremaking supervisor. Reviewing historical core and mold scrap
records, I noticed that the frequency of such incidents begins to
increase in the spring, peaks during mid-summer, declines during
the fall, and reaches a bottom throughout the winter. I have
looked at all of our procedures and followed-up with employees
working in these areas. However, I still can’t put my finger on what
is actually happening. Where should I look next?
A: I suggest that you start looking at those areas that impact
the quality of your plant air and the humidity levels in the
work environment.
The worst times for core and
mold production in the foundry
environment are the transition
periods between spring and
summer, and between sum-
mer and fall. Warm air contains
much more moisture than cold
air and the levels of moisture in
that air can have a significant
impact on those processes. For
example, many no-bake pro-
cesses take longer to strip, shell
cores suddenly suffer from peel-
Plant air and the humidity levels in the work environment affect the quality of
back, cold box cores become cores, molds, and corresponding scrap rates.
weaker, and storage of cores
and molds made with inorganic binder systems becomes problem-
atic. All of these effects occur because the moisture capacity of the
air has undergone a dramatic change.
The subject of compressed air and the effects of humidity is a
complex one. To understand better and control the processes de-
pendent on air and the working environment, one first must under-
stand some basic terms and principles. From there a fundamental
understanding of why seasonal changes and increased amounts of
moisture in the air can have such a dramatic impact on cores, molds,
and corresponding scrap rates can be obtained.
Moisture capacity is the amount of moisture air can hold at a spe-
cific temperature. Air always will hold as much moisture as possible
at any given temperature. Warm air will contain much more moisture
than cold air. For example, air at 80°F has four times the moisture ca-
pacity than air at 40°F. Relative humidity is a percent value identifying
the amount of moisture present in the air based in its temperature.
Dew point is the temperature at which the moisture present in the
air begins to transform from a vapor to a liquid. Condensation is
F O U N D RY M A N A G E M E N T & T E C H N O L O G Y | F O U N D RY M A G . C O M | J A N U A RY 2 0 2 1
ADVERTORIAL
the process of water molecules transforming from a vapor stage
into a liquid. The effect of temperature on moisture-saturated air is
especially important to the understanding of the core room and mold
line problems caused by weather changes. This can be shown in the
following example.
Summer air at elevated temperatures has a high moisture capac-
ity. The relative humidity during normal summer days can be quite
high and on regular occasions exceed 90%RH. When summer air
begins to cool in the evening and overnight, the dew point of that air
is easily reached. A casual observer will note the formation of dew
on the grass and the formation of water on building structures at this
time. This is the point at which condensation occurs. The effect is
most pronounced when there are sudden increases in weather tem-
perature and the presence of
high humidity on rainy, muggy
days.
The biggest mistakes that a
foundry man can make at this
time are: a) to believe that your
facility’s compressed air dryers
are maintained and capable of
providing the dry the air used
in core-making processes; and,
b) to believe that your mold-
making procedures are static
and do not require any adjust-
ments based on the conditions.
The first thing to do is to con-
sult with your facility engineering and maintenance teams. They can
provide support in terms of analyzing the situation to determine if the
plant’s main compressed-air dryer is functioning at peak capacity.
They also can assist in evaluating the satellite regenerative dryers
used to deliver dry air to your coremaking processes. Also, it would
make sense to reach out to the supplier of binders and catalysts
used for moldmaking. The technical service that they can provide
will allow you to make adjustments with respect to the binder types,
catalyst types, and amounts being used.
The bottom line is that that insights learned from these expert
sources can help you make the adjustments necessary to keep your
processes under control during these difficult times of the year.
Seek metalcasting solutions … discuss ideas
and new technologies with ASK Chemicals
Join the Conversation …
Sumbit your questions
at www.foundrymag.com
 CASTING TECHNOLOGY
BEYOND TOMORROW

Are you
READY
for tailor-made
services?

Ideally positioned thanks to perfectly tailored

technical services
In the future, anyone who wants to be more than just well positioned requires reliable partners and tailor-
made services. We are always there for you, offering a comprehensive range of technical services that look
at your entire production process. This opens up a whole world of new possibilities – from cost savings to
increased productivity.

ASK Chemicals experts look forward to hearing from you:

Phone: +1 800-848-7485
E-mail: info@ask-chemicals.com
www.ask-chemicals.com/beyondtomorrow
^ CONTENTS
Volume 149 Number 1

14 SAND & BINDERS MANAGEMENT & TECHNOLOGY

10 Evaluating PUCB Environmental Advantages 2 SUMMIT PARK DRIVE, SUITE 300
The most widely used, organic chemical binder process is noted CLEVELAND, OH 44131
for being versatile, productive, and cost-efficient, and recent PH 234/466-0200
developments are adding to the advantages. WWW.FOUNDRYMAG.COM
EDITORIAL STAFF
11 Eliminating Green-Sand Variation
at the Molding Location EDITOR ROBERT BROOKS
Proactively monitoring sand temperature, compactability, rbrooks@endeavorb2b.com
moisture content, green compressive strength, and permeability
will eliminate green-sand variation at the molding location. GRAPHICS EDITOR BILL SZILAGYI
bszilagyi@endeavorb2b.com
CORE & MOLDS
12 Advances in Sand Reclamation
Now is the time to look at newer sand reclamation technologies,
to reduce cost and environmental impacts, and to enhance casting
quality.
22 14 Additive Manufacturing's Impact
on Investment Casting
What started as a way to deliver 3D prototypes has evolved to a
new process route, driving new creative approaches and delivering
time- and cost-saving advantages.
MELTING/POURING
18 Selecting the Right Unit for Efficient Induction Melting
Coreless-type induction furnaces may be slightly less efficient than
core-type channel furnaces but they are often more flexible. It is
important to know and understand the difference.

20 Advantages of Collapsible Breaker Cores

The steady demand for thin-wall, complex castings prompted the
development of feeders with a patented collapsible metal breaker
core design, now improved based on the experience of spot-
feeding in high-pressure molding lines.
29
22 Global Impact of Redux Fluxes to Reduce Slag Build-up
Newly engineered fluxes can extend refractory life in coreless
induction furnaces, prolong ladle service life of pouring ladles, and
significantly reduce slag and/or dross.
24 Larger Automotive Castings Drive Innovation in
Molten Metal Delivery
Automotive design trends are fulfilling long-standing cost and
safety objectives in auto production — which is guiding further
advances in casting processes.
SHAKEOUT
28 A New Approach to Sand Reclamation
An innovative, small-footprint attrition mill offers foundries a cost-
effective, customizable, and reliable route that makes recovering
sand and metal a no-brainer.
FINISHING
36 29 How Vacuum Impregnation Supports
Environmental Responsibility
Automotive casting production calls for aggressive efforts to
eliminate waste and conserve resources, and manufacturers need
to make their processes cleaner, safer, and more resource-efficient.
INFORMATION TECHNOLOGY
30 Designing Feeding Systems for Investment Castings
In just a few minutes, simulation software can indicate gate and
feeder-bar sizes, and gates can be positioned to provide feed metal
to the recommended areas of the prospective casting.
31 Using Virtual Reality in Metalcasting Environments
AR/VR technologies are helping manufacturers to increase their
digital transformation — and emerging as the major change
agent for production layouts, custom equipment development,
and training.
ON THE COVER: Design by Bill
Szilagyi, graphics editor.
Visit the Foundry Management & Technology
website www.foundrymag.com for the online
suppliers directory.
Editor’s Note.................................... 4
Newsmakers .................................... 6
Advertiser Index ........................... 32
Business Staff................................ 33
Product Express ............................ 34
Closing Comment ......................... 36
FOUNDRY MANAGEMENT & TECHNOLOGY (ISSN
0360-8999) is published monthly by Endeavor
Business Media, 1233 Janesville Ave, Fort Atkin-
son, WI, 53538. Periodicals Postage Paid at Fort
Atkinson, WI. and at additional mailing offices.
Printed in the U.S.A. Copyright 2021 by Endeavor
Business Media. Canadian GST# R126431964.
Subscriptions: Solicited at no charge from quali-
fied persons in the North American foundry and
diecasting industries. All others pay $92 — one
year; $10 — single copy. Canada: $59 — one year;
$15 — single copy. International: $79 — one year;
$20 — single copy. Send subscription payment
to: FOUNDRY MANAGEMENT & TECHNOLOGY,
PO Box 3257, Northbrook, IL 60065-3257; Phone:
800-262-1954 or 913-967-1719; Fax: 800-633-6219
or 913-967-1901; Email customersupport@en-
deavorb2b.com.
Po s t m a s te r : S e n d a d d re s s c h a n ge s to
FOUNDRY MANAGEMENT & TECHNOLOGY, PO
Box 3257, Northbrook, IL 60065-3257.

2 F O U N D RY M A N A G E M E N T & T E C H N O L O G Y | F O U N D RY M A G . C O M | J A N U A RY 2 0 2 1
^ EDITOR’S NOTE
The Scale of Our Problems
J
anuary used to be a slow-starter. People would
attach an extra day or three to the customary New
Year holiday, and office hours would start and end
a bit off-schedule. School would not begin again five
or six days. Manufacturing operations would schedule
maintenance projects during the days after Christmas
(as many do still…) and that sometimes led to de-
layed restarts. Stores would have a slightly disheveled
look, with overstocked clothing and housewares now
marked down, encouraging customers to snap up
bargains. TV schedules would show lots of reruns
until NFL playoff games and replacement series were
ready to begin. Everyone understood that we all were
moving slowly because there was nothing too import-
ant to be rushed and we could certainly catch up to all
of it next week. By then, we might have managed to
date our checks properly.
In the magazine business, this atmosphere generated
a lot of special features: trends to look for in business,
entertainment, fashion, etc. “In and Out” lists would tag
things you should know or forget if you wanted to ap-
pear up-to-date. It was in this context that FM&T devel-
oped the annual Idea Book project – to illuminate what
was happening to shape or advance different metalcast-
ing technologies, and to bring interesting and relevant
concepts to an audience focused on those topics, and
to lay a foundation for new business, new projects, and
new possibilities. We certainly hope it will do that still,
but the times have changed, to say the least.
Presenting relevant topics this way was right for
January, a fresh-start/clean-slate approach that suited
the readers’ interests — and a good contrast with the
prevailing form of magazine journalism, which focused
on “problems.” (Story pitch: Do you have X problem?
Here is the solution.) There’s nothing wrong with that
approach – and it’s still quite effective if the source is
reliable and the topic is matched to the right audience.
But bringing a topic and an audience together at just the
right time is more difficult than it used to be; January
is really a non-starter now, because it’s not so differ-
ent from December and no one is looking toward any
significant changes ahead. There are no consistent,
recognizable schedules for work, school, entertainment
programming, shopping hours, and so forth.
Time frames no longer exist as they once did. Now
4 F O U N D RY M A N A G E M E N T & T E C H N O L O G Y | F O U N D RY M A G . C O M | J A N U A RY 2 0 2 1
Robert Brooks
Editor
we let the daily doom reports of new infection and
hospitalization figures mark our progress, along with
evil-versus-evil score updates from politics, and the
grievances of one individual after another denied his
or her full agency by some heretofore undocumented
systemic injustice.
As I’ve written before, disowning or denigrating
our shared history means living outside of time. It
leaves us with no choice but to exist in an anxious and
nasty present, frozen by caution and with no hope for
a better future.
The timing is only half the point, however. The
“problems” that a magazine addresses have to be
matched to its audience – meaning the problems have
to have an appropriate scale. Some problems are so
vast they cannot be clearly or satisfyingly addressed.
That’s why cable news stick to agendas that will keep
their viewers from changing the channel. Other prob-
lems are so inconsequential that they become the af-
finities of individuals or groups. If a problem is too
big and unmanageable, the source of the solution can-
not be trusted. If the problem is too small and trivial,
the source should be ignored.
January used to be a break in the action that allowed
us to assess all this, a time-out before once again tack-
ling the things we identified for fixing or improving,
or putting forth the alternatives we intended to estab-
lish. It was a time for building confidence and setting
clear programs.
It can be that again, in some sense, if we approach
our lives and work with more humility and greater
ambition. Living and working on-demand fulfills the
risk-averse, resource-conscious agenda, but it does
not satisfy the individual desire for change.
The personal reward of problem-solving is rarer
now that we rely on Smartphone apps and various
A.I. functions, but there are problems worthy of our
attention and application. We become subjects to our
problems if we do not.
We should reacquaint ourselves with those issues
that will enlighten us and get behind ideas that can
address problems worthy of our efforts. Having done
that, we can begin to feel confident about the new
insights we gain and the next challenges we can
approach.
 ®

Master Planning
Facility Planning
Engineering Design
Concept Layouts
Feasibility Studies
Ferrous & Non-Ferrous

We are The Foundry

Design Specialists
316 Maxwell Rd, Suite 500, Alpharetta, GA 30009, Phone: 770.667.4545 Fax: 770.667.4544
e-mail: engineering@foundrysd.com, www.foundrysd.com
^ NEWS MAKERS

Italpresse Adds Sales
Director - Americas
talpresse Gauss appointed Michael Mar-
I tin to spearhead its expansion in the U.S.,
Canada, Mexico, and South America as its
sales director for the Americas. The Italian
Martin
developer of diecasting machinery noted it
aims to build on its U.S.-
based parts and service
capabilities by growing
its foundry customer
base in the region.
Martin has over 20
years’ industry expe-
rience, spanning die-
casting machinery and peripherals, manu-
facturing process aids, and metal-working
chemicals. He previously held senior sales
and account management positions at Chem-
Trend, Nica USA, MPM Sales Group, and
UBE Machinery Inc.
Italpresse Gauss offers high-pressure,
low-pressure, and gravity diecasting tech-
nologies, as well as fully automated cells and
Industry 4.0 software and technologies. It is
a part of the Norican Group of companies,
which includes DISA, StrikoWestofen, and
Wheelabrator.

3D Systems Names
Heads for Business Units
s part of 3D Systems’ plan to restructure
A with two market-focused business units,
the company named Menno Ellis, executive
vice president, Healthcare Solutions, and
Reji Puthenveetil, executive vice president,
Industrial Solutions.
Ellis is responsible for 3D Systems’ Den-
tal, Medical Device, and Simulation busi-
nesses. He joined 3DS in December 2016 as
senior vice president Strategy and Vertical
Markets and then served as SVP of the Plas-
tics business. He holds undergraduate and
graduate business degrees from the Whar-
ton School of the Univ.
of Pennsylvania and the
Ross School of the Univ.
of Michigan.
Puthenveetil joined
3DS on October 1, 2020,
as head of the Industrial
Ellis Solutions Group, which
covers aerospace and de-
fense, ground transpor-
tation,energy, high-tech
industries, and jewelry.
Previously he spent more
than 25 years in manage-
ment consulting and op-
Puthenveetil
erational roles develop-
ing strategies for growth
and organizational capability. He holds a
bachelor’s degree in communications from
Wingate College and a master’s degree in
business administration from Wake Forest
University.

6 F O U N D RY M A N A G E M E N T & T E C H N O L O G Y | F O U N D RY M A G . C O M | J A N U A RY 2 0 2 1
With the
Rotary Lump Crusher / CHEMICALLY-BONDED LUMPS
Sand Reclaimer there is

Equipment & Capital outlay

Sand & Binder costs
Energy consumption
Air-Borne Silica Dust

Capabilities for Faster Payback

 'HƂEKGPE[4GNKCDKNKV[
CLEAN TRAMP METAL FOR REMELT
Operational & Maintenance Savings
Throughput & Greater Yield

Other systems achieve 50% of the

required throughput, where
often exceeds their rated capacity.
By combining Lump Reduction,
Scrubbing, Dual Sand Screening,
%NCUUKƂECVKQPCPF/GVCNNKE5GRCTCVKQP
UKIPKƂECPVƃQQTURCEGKUUCXGFCUYGNN
HIGH QUALITY RECLAIMED SAND

DIDION INTERNATIONAL INC. phone, 636.278.8700

Riverside Industrial Centre fax, 636.278.3155
7000 West Geneva Drive email, info@didion.com
St. Peters, MO 63376 USA web, www.didion.com
 LUMP INTAKE

Patented multi-chamber design

Crushes, Scrubs, Separates,
Screens, and Classifies
Huge savings in sand purchases,
disposal costs, and binder
Automatic separation of tramp
metal and debris
Reduces air-borne silica dust for
safer, cleaner workplace
Highly efficient air-wash separation
LUMP REDUCTION CHAMBER
removes dust, debris, and fines

“Most kids want a puppy for Christmas.

I always wanted a DIDION ®.”
John Alexander,
Alexander Mill Services

HIGH QUALITY RECLAIMED SAND

Sand and Binders
Evaluating Phenolic Urethane Cold Box
Environmental Advantages
The most widely used, organic chemical binder process is noted for being versatility, productivity,
and cost-efficiency, and recent developments are adding to the advantages.
T
he Phenolic Urethane Cold Box process (PUCB) is the most
widely used, organic chemical process for coremaking in
North America due to its versatility, high productivity, and
cost-efficiency. But, the appreciation for PUCB systems primarily
comes from their faster cycle times; applicability for ferrous and
nonferrous casting; excellent performance for highly complex cores;
high mechanical strength; and effective thermal characteristics.
Some of the common challenges associated with PUCB binder
Enhanced Characteristics Benefits to the
coremaking / casting
process
Excellent sand flowability Helps with blowing dense
cores
High thermal stability Increased in dimensional
accuracy in complex
castings such as thin walled
pieces.
Low gas formation at Fewer gas related defects
casting such as scabbing, gas
bubbles, and pinholes.
Low condensable formation Results in less cleaning
efforts and reduces
accumulation of
condensables in the
ductwork.
Table 1 – Main performance enhancements in silicate cold box systems
systems include high emissions profiles; higher smoke/odor in the
coremaking and casting process; and the possibility of developing
higher levels of condensables. Additionally, these binder systems are
susceptible to sand chemical and physical characteristics. Changes
in sand profile can significantly impact the sand’s tensile strength,
core resistance, and ultimately to the core and casting quality.
The primary classifications for PUCB binder systems are:
1. Sigmacure PUCB binder systems: hydrocarbon or aromatic
solvent package. Used for over 50 years, these are the most common
foundry PUCB systems. The advantages are lower cost and highly
flexible for many materials and methods.
2. Bioset PUCB binder systems: biodiesel, plant-based or ali-
phatic solvent package. These systems have been in use for over 20
years and are appreciated for their high performance benefits. The
advantages are lower emissions, volatile organic content (VOC) and
hazardous air pollutants (HAPs) at coremaking; fast cycle times; high
mechanical strengths; and good bench life for the sand-binder mix.
3. Silcure PUCB binder systems: inorganic solvent package. Fur-
nished with inorganic solvents this type of PUCB system offers many
environmental and performance advantages and considered to be an
1 0 F O U N D RY M A N A G E M E N T & T E C H N O L O G Y | F O U N D RY M A G . C O M | J A N U A RY 2 0 2 1
ideal bridge between PUCB binders and inorganic high productivity
binder systems (IOB.) The advantages are that these binders offer the
lowest level of odor and smoke generated during the coremaking and
casting processes, the potential for lower total VOC profiles.
Advancements in PUCB technologies. Minimizing the environ-
mental health and safety (EHS) impact and enhancing performance
properties have prompted many recent PUCB binder advances. All
chemical binder systems based on organic materials (carbon-based)
will generate some emissions. Inorganic systems (IOB) address
many of the emissions concerns, but higher capital cost and limita-
tions in use (light alloys) have prevented these systems from becom-
ing more popular, despite their important environmental advantages.
While IOB systems may be a feasible alternative in the long term,
presently there are several practical, commercially available solu-
tions that the industry could adopt depending on the specific need.
The majority of PUCB systems have reduced the emissions profile
with lower phenol and formaldehyde contents.
There are PUCB systems that have adopted naphthalene-de-
pleted solvents to help reduce BTX (benzene, toluene, and xylene)
HAPs. Renewable products such as biodiesel solvents also have
helped to reduce the VOC and HAP profile of the binder system.
Silicate solvents. Silicatic solvents are inorganic solvents that
have important environmental advantages and are the perfect bridge
between PUCB and IOB systems. Advantages include the lowest
smoke and odor profile at pouring, cooling, and shakeout. These
binders also exhibit one of the lowest VOC profiles when total
VOCs are taken into consideration — from coremaking to pouring,
cooling, and shakeout. Relevant experience gathered in the use of
this type of cold-box systems have shown low condensate profiles.
Bench life. Extreme heat and humidity are common challenges in
coremaking. The capacity of the sand-resin mix to withstand such
conditions to produce quality cores, after the sand and chemicals are
mixed, is paramount for a sustainable process. Newer PUCB tech-
nologies are designed with that in mind — to maintain a workable
bench life producing quality cores under extreme conditions.
Dimensional tolerances. As the castings produced become
lighter and more complex, the binder system must conform to in-
creasingly higher tolerances. Newer PUCB systems are engineered
to assist in minimizing shrinkage defects in light-alloy castings.
Productivity. Gains in curing speed often are hampered by lack of
wipe-off, release, or similar properties. Newer PUCB systems have
demonstrated significant advances in all of these characteristics,
which have resulted in reduced to a minimum the downtime related
to wipe-off and/or release.
Learn more at www.ha-international.com
Eliminating Green-Sand Variation
at the Molding Location
Proactively monitoring sand temperature, compactability, moisture content, green compressive strength,
and permeability will eliminate green-sand variation at the molding location.

A
common problem for metalcasters is proper green- anywhere, such as at a jolt squeeze line or molding machine.
sand preparation. Even Sinto has provided DST-II
when the sand is prepared units to smaller foundries that
correctly, how can the foundry do not have in-house established
operators determine the accuracy testing procedures: foundries can
of the formulation? How are the process real-time data of the sand
results recorded for repeatability they are using and receive the re-
purposes? How are changes im- sults within 90 seconds for results.
plemented at the muller? Many Sinto has successfully used the
foundries monitor sand by how testing unit for customers install-
the molding operation is perform- ing new automated molding line,
ing. Proactive preparation of the accurately analyzing the sand and
green sand, accurately and consis- removing any variable from the
tently, will eliminate green-sand start-up procedure when launch-
variation at the molding location. ing new projects. With accurate
Typical sand parameters presented in the DST-II graphic
Removing unwanted variations display. data, the new machinery can be
from the green-sand properties is launched quickly and reliably.
critical to producing consistent castings and running a success- The features of the
ful foundry. Many factors contribute to variations in the way DST-II in-line digital
that green sand is prepared and delivered. Foundries usually sand testing unit in-
have equipment from different manufacturers and perform dif- clude self-calibration
ferent types of molding processes, which means they prepare and repeatable, accu-
the green sand from various recipes. It’s important to deter- rate readings. It can
mine what type of sand works best for each molding system. be interfaced with the
Many foundries will batch mull sand for each molding line; muller controls to adjust
which is delivered and stored in the small sand hopper at the for variability between
machine. This process is a simple solution for individual sand muller and molding
properties at each molding location. If you do not have the machine. A load cell
means to batch-mull green sand, then sand must be prepared is used to conform test
in a manner that will provide best properties for all equipment. sample height, which
Due to the narrow window of variation of the sand parameters, eliminates variance in-
close monitoring of the sand will be required. troduced by manually
To determine which green-sand recipe is right for a foundry, sampling, resulting in
establish what type of sand is to be used and how much clay The DST-II series sand tester. highly accurate results.
content is needed. On a daily basis, green-sand preparation Measurement data can
has five critical factors that need to be monitored closely for be exported via USB, for easy data transfer to a quality-con-
proper molding: sand temperature, compactability, moisture trol database.
content, green compressive strength, and permeability. Accurate green-sand testing provides foundries with im-
It is understood that measurement can be performed at the mediate return on investment for a small investment. The
muller but to get an accurate reading of these five components, DST-II is a solution that can be implemented at a reasonable
it would be best to take a reading at the point that the green cost, and the ROI can be calculated by the signification
sand is used. The Sinto DST-II series allows foundry operators reduction in scrap due to sand defects, as well as scrapped
to take readings of the sand make-up at any point in the system molds.
because it is a portable testing unit. Unlike the fixed sand-test- Contact sales@sintoamerica.com for more information,
ing systems that fixed in one place, the DST-II can be used or visit www.sintoamerica.com

J A N U A RY 2 0 2 1 | F O U N D RY M A G . C O M | F O U N D RY M A N A G E M E N T & T E C H N O L O G Y 1 1
Cores and Molds

Advances in Sand Reclamation

Now is the time to look at newer sand reclamation technologies, to reduce cost and
environmental impacts, and to enhance casting quality.
Jack Palmer

that the cost of entry can be quite high, seemingly out

There are two basic types of sand reclamation systems – mechanical and thermal –
to treat chemically bonded sand for reuse in molding and coremaking.
ost everyone realizes that sand reclamation is nec-
of reach. However, now there are many different levels
of entry, as well as newer technologies to meet ROI
requirements for both jobbing and larger-volume pro-
duction foundries, reclamation solutions that are both
bottom-line friendly and quality enhancing.
Sand reclamation systems. Sand reclamation in-
volves physical, chemical, or thermal treatment of sand
for reuse in molding and coremaking. There are two
major types of systems, mechanical and thermal.
A mechanical system physically breaks down lumps
of spent casting sand, into clean sand. A thermal recla-
mation system takes sand that has been broken down
to grain size in a mechanical reclamation system and
adds heat energy to burn off the remaining resins.
Before sand can be processed in a thermal system,
lumps must be reduced in a mechanical system, with
the following sequence of components: shakeout deck;

M essary for cost reducing and environmental require- attrition mill; elevating device; surge hopper; magnetic sep-
ments. While the popularity of sand reclamation arator; agglomerate screener; fluid bed classifier (cooling
certainly resulted from increasing sand prices (caused primar- optional); elevating or pneumatic transportation device;
ily by the demand for fracking), there are few processes that bulk storage silo for mechanically reclaimed sand; and dust
provide as many immediate benefits as sand reclamation. collector.
Reducing the cost of sand is by far the most attractive con- Thermal reclamation system. A typical thermal recla-
sideration for sand reclamation, though lowering disposal and mation system will include the following sequence of com-
transportation costs are equally attractive. Couple these with ponents: surge hopper for supply; magnetic separator (if not
reducing your environmental footprint and you realize that already included upstream); metered feed mechanism; heating
reclaiming sand is just good business. zone; cooling zone; elevating or pneumatic transportation de-
One of the most overlooked benefits from sand reclamation vice; bulk storage silo for thermally reclaimed sand; and dust
is quality assurance. Controlling your materials through an collector (likely high temperature.)
in-house system will enhance the quality of your castings; If a thermal reclamation system is included, some foundries
because better sand makes better castings. will thermally reclaim all sand; others will thermally reclaim
Higher casting quality. One of the main advantages of a portion of the sand and then blend it into the system in order
thermally reclaimed sand is that it helps foundries lessen to control their “loss on ignition” (LOI) readings. This choice
expansion defects. This is especially critical for cast surfaces also will affect the components included in a typical system,
of impellors, volutes, etc., and so it is common for found- and exactly where the sand stream exits the mechanical re-
ries to run all-new sand through the thermal system for this claimer and enters the thermal reclaimer.
reason. Benefits of thermally reclaiming all sand include the con-
Thermally reclaimed sand also requires substantially less sistency of sand going into the mold, and no concerns for LOI.
binder to achieve acceptable strengths compared to new sand, Also, the equipment for mixing, storage, and sand transporta-
which produces stronger molds and cores. With less binder tion are generally simpler, as there is no need to have daytanks
needed, there is the additional benefit of less smoke and odor. for both mechanically and thermally reclaimed sand above the
Fewer chemical additives also mean better sand grain, fewer mixer. The operator simply feeds a single sand mixture into
defects, less grinding/welding, and better surface finishes. all molds, rather than switching from new to mechanically
With all of these advantages, the question emerges: Why reclaimed at a specified point in the mold.
aren’t all foundries reclaiming spent sand? The easy answer is One disadvantage is that the thermal reclaimer will need to

1 2 F O U N D RY M A N A G E M E N T & T E C H N O L O G Y | F O U N D RY M A G . C O M | J A N U A RY 2 0 2 1
WORK FASTER. AND SMARTER.
NOT HARDER.

Find out how B&L can

help you make better
decisions … faster.

Odyssey ERP for Metalcasters

4707 Rambo Rd. | Bridgman, MI 49106-9723 | 269.465.6207 | BLInfo.com

Cores and Molds
be larger in order to process all sand.
There are three primary types of thermal reclamation sys-
tems: electric, for small applications up to around 600 lbs./hr,
or roughly equal to a truckload of sand per week; gas-fired, for
larger applications; and either a fluid-bed style or a rotating
calciner.
While impact scrubbers have been around for a while, they
have fallen out of favor with the advent of better vibratory
technology, which quite efficiently scrubs the binder off the
grains.
There is new, patented technology that has the potential
to eliminate the need for thermal reclamation to reduce LOI
below critical. This Secondary Reclamation System (SRS) is
Additive Manufacturing’s Impact on
Investment Casting
What started as a way to deliver 3D prototypes has evolved to a new process route, driving new
creative approaches and delivering time- and cost-saving advantages.
Evan Kuester
AM makes it possible to avoid the time and expense of machining injection-
molding tools for wax patterns. Thanks to advanced software, hardware,
and materials, foundries can proceed directly from the CAD to the pattern.
I
nvestment casting has been used worldwide for thousands
of years to form a range of parts, establishing the basis for
a variety of applications, and industries. Traditionally, this
process requires creating a mold into which a molten alloy
can be poured. The workflows required to manufacture these
molds have remained largely the same since the start of the
Industrial Revolution.
Now, due to relatively recent advancements in the field of
additive manufacturing (AM), what started as a method for de-
livering simple, three-dimensional prototypes has evolved into
an effective process for supplying multiple industries, including
1 4 F O U N D RY M A N A G E M E N T & T E C H N O L O G Y | F O U N D RY M A G . C O M | J A N U A RY 2 0 2 1
used after the sand is broken down to grain size. It is an im-
pact-type machine but requires almost no compressed air or
blower air. Scrubbing is accomplished with multiple, facing
ceramic pates that are timed to come together in a synchro-
nous way. Sand is fed between the plates and is efficiently
scrubbed, then falls to the bottom of the unit where it is
classified (dedusted) and cooled. All the sand goes through
the SRS every pass and is carefully monitored to ensure the
LOI is below critical levels — defined as that point at which
casting defects may begin to develop.
Jack Palmer is the president of Palmer Manufactur-
ing & Supply Inc., Springfield, OH. Learn more at www.
palmermfg.com.
Additive Manufacturing shortens the time from product development to
manufacturing of the final components. It allows designers and engineers
to iterate a part’s fit, form, and function before initiating manufacturing.
investment casting foundries. Additive Manufacturing, some-
times called 3D Printing, is used today to shorten the time for
everything from the product development to the manufacturing
of the final components. It’s a new manufacturing process that
allows designers and engineers to rapidly iterate a part’s fit,
form, and function before initiating manufacturing of those same
components. And, the scope of applications is growing due to
continuing advances in software, hardware, and materials.
Transformative power. One of the most impactful changes
Additive Manufacturing has brought to investment casting
is the ability to skip the expensive process of machining in-
jection-molding tools for wax patterns. Thanks to advanced One of the best aspects of using AM to support investment
software, hardware, and materials, foundries can proceed di- casting is the ability to create components and designs in ma-
rectly from the CAD to the pattern, saving time and money for terials that were not traditionally available due to limitations
everyone involved. This sequence is referred to as “tool-less” in the manufacturing process. Cutting-edge, generative design
pattern creation, and it has opened up various applications and techniques like “topology optimization” may be limited by
development cycles that were previously too cost-prohibitive both the size of the machines and the alloys available to metal
to explore. additive processes. Inversely, traditional investment casting
Another aspect of tool-less pattern creation is the speed workflows do not easily allow for creation of wax patterns at
at which these patterns can be produced. Traditionally, the the level of complexity required for these designs. However,
lead time for a CNC-machined, metal injection tool for a wax by adopting additive manufacturing and investment casting
pattern is up to two weeks, or even more. However, with the together, foundries have been able to achieve the best of both
advent of AM patterns, the production can be done in hours or possibilities: designs that distinguish from their competitors are
days. This drastic increase in speed not only allows suppliers possible while using a reliable and predictable casting process,
to deliver products faster but, combined and for any specified alloy.
with tool-less pattern creation, allows Not only has additive manufactur-
engineers to iterate their designs faster. ing opened up new design possibilities
This ensures the final designs will per- for investment casting, but the efficient
form more reliably -- and it means that use of material in the creation of the
the finished parts can be certified faster. patterns means they are easier to han-
This so-called “digital foundry” has dle than traditional wax patterns. Com-
changed the way many manufacturers prised mostly of air, these additively
operate and structure their develop- manufactured patterns can easily be
ment cycles. Several aerospace firms lifted by one person and moved quickly
have adopted faster and more aggressive across a shop floor, or easily lifted by an
engineering cycles due to the time and automated shelling system. Reducing
cost savings afforded by additive-man- the loads carried by robots can extend
ufactured patterns. Their development the service life of those systems or al-
Part designers have fewer limitations for the
teams have embraced the Silicon Val- shapes that can be produced by casting or low the same job to be done by a less
ley mentality of “move fast and break machining ... expensive machine. Finally, lightweight
things’’ – which in manufacturing is only parts also are easy to ship and can be
achievable because of AM. transported almost anywhere if a printer
As the time to go from CAD to a cast- is not available.
ing becomes a critical factor for many Looking forward. As AM solutions
projects, so will the demand for faster grow and evolve, the further integration
turnaround times for the castings. There of printing technologies, material science,
have been several circumstances where and software tools will continue to offer
the designs of components have evolved an expanding portfolio of solutions that
so rapidly that multiple iterations have support additive manufacturing of pat-
been created and tested within a week, terns. Additionally, as additive processes
creating development scenario that would improve, the time and cost to produce a
not have been possible without AM. ... and they can consolidate shapes to reduce pattern will decrease, so investment cast-
component weight and assembly costs.
The possibilities revealed by addi- ers and other manufacturers can do more
tive-manufacturing patterns allow for with fewer resources.
greater design freedom too. Components that have always Driving the cause of “more with less” is a generation of
been assembled from multiple parts now can be designed as a designers and engineers who have grown up in a world where
single object, and such objects can be far more complex than AM is a standard manufacturing process. Many of the parts
what was achievable previously. they are engineering now are no longer limited to the tooling
No longer limited to the shapes that can be produced using constraints that have been standard for investment casting,
a CNC machine, designers and engineers now create a wide and as their efforts progress, designs based in Additive Manu-
variety of new designs -- from complex injection manifolds facturing will grow in demand — and the benefits of a digital
with conformal water jackets that operate longer at higher tem- foundry will become clearer.
peratures, to advanced part consolidation techniques that save Evan Kuester is a Senior Advanced Applications Engineer
aerospace companies time and money in the cost of assembly with 3D Systems. Contact him at evan.kuester@3dsystems.
for complex components and in advanced weight reduction. com or visit www.3Dsystems.com.

J A N U A RY 2 0 2 1 | F O U N D RY M A G . C O M | F O U N D RY M A N A G E M E N T & T E C H N O L O G Y 1 5
Furnace Charge
Feeders
Rotary Drum
Feeders
Shot Blast
Feeders

Also Featuring:
Mold Dump Conveyors
Casting Cooling Conveyors
Separating / Sorting Conveyors
Multi-Directional Conveyors
Vibratory Screeners
Undermill Oscillators

Decades of innovative engineering:

• Dyna Sync Dynamic Drive System™
• Extra Heavy Duty construction for low maintenance
• Energy Savings for lower operating costs
• Better Designs for optimum performance
• Best Value over competitive brands

CONVEYOR DYNAMICS CORPORATION

Riverside Industrial Centre
7000 West Geneva Drive
St. Peters, MO 63376 USA
phone, 636.279.1111 fax, 636.279.1121
www.conveyordynamicscorp.com
info@conveyordynamicscorp.com
 Furnace Charge Feeder with Hopper

Rotary Drum Feeder

Mold Dump Conveyor with Heaters

CONVEYOR DYNAMICS CORPORATION

Riverside Industrial Centre
7000 West Geneva Drive
St. Peters, MO 63376 USA
phone, 636.279.1111 fax, 636.279.1121
www.conveyordynamicscorp.com
info@conveyordynamicscorp.com
Melting

Selecting the Right Unit for

Efficient Induction Melting
Coreless-type induction furnaces may be slightly less efficient than core-type channel furnaces
but they are often more flexible. It is important to know and understand the difference.
Michael Fanz-Huster

T
here are two basic types of induction melting furnaces that
have been in use since the early 1900s. First came channel
furnaces, operating with mains frequency, and then
many foundries switched to smaller coreless furnaces,
for which a range of frequencies (from medium to high) were
used. Channel furnaces were originally developed to melt brass but
now are commonly used for copper, bronzes, zinc, aluminum and
iron. Coreless furnaces are commonly used for virtually all metals.
Channel furnaces produce heat for melting by utilizing the princi-
ple of the short-circuited iron core transformer. Alternating current is
passed through a multiple-turn primary coil surrounding an iron core.
The secondary is a loop of molten metal surrounding the primary and
the core. Current flowing through the primary induces a much larger
current in the metal loop, whose resistance creates heat for melting.
Core-Type Channel — Channel furnaces are the most efficient
type of induction furnace because their iron core concentrates mag-
netic flux in the molten loop, ensuring maximum power transfer
from primary to secondary. Efficiency in the use of power can be as
high as 95 to 98%.
Channel furnaces are most effective for high-production opera-
tions that need: a large throughput of metal; continuous and multi-
shift casting schedules; few alloy changes; holding capacity for shift
melting operations to take advantage of off-peak energy savings; and
power demand limiting. Channel furnaces are an economical way to
hold a large quantity of molten metal for an extended period of time
to provide a continuous supply of ready-to-pour metal, seven days a
week. Melting can take place during off-peak energy demand periods
in a coreless furnace and then the molten metal can be stored in the
channel furnace and tapped for production during on-peak hours.
However, an essential loop of metal must be maintained con-
tinuously in a channel furnace. If allowed to freeze, extreme care
is necessary in remelting because the loop may rupture and disrupt
the circuit. This could require extensive work to restore the loop, or
the furnace may need to be disassembled completely and relined.
Consequently, channel furnaces rarely are permitted to cool, which
makes alloy changes difficult because a heel of molten metal always
is required.
tend several years and for millions of pounds of molten metal, with
proper maintenance. Channel furnaces are ideally suited to melting
a single alloy as a holding vessel or as a pressure-pour furnace.
Coreless-Type — A coreless induction furnace operates at low,
intermediate and high frequencies — from 60 to 10,000 cycles/
second — and is unmatched for flexibility. It also operates by trans-
former action, but in this case it is similar to an air-core transformer.
The primary coil induces current directly in the metal charge, which
is contained in an unobstructed crucible or refractory lining. There
is no internal melting loop or channel. The primary winding is a
water-cooled copper coil surrounding the outside of the crucible or
refractory lining.
The coreless furnace can be started cold and usually is poured
empty. This greatly simplifies alloy changes and makes it possible to
shut down as desired.
Linings of coreless furnaces may be as durable as core-type fur-
nace linings in applications where a molten charge is maintained 24
hours a day. Because of alloy changes or analysis control, however,
batch melting is the usual practice and the recurring heating and
cooling results in less lining life. On the other hand, these linings are
considerably less expensive and can be changed quickly.
Because there is no flux-concentrating core as on core-type
furnaces, the efficiency of the coreless furnace usually is lower
than that of core-type furnaces. Normal efficiency is approxi-
mately 75%. Smaller coreless furnaces are designed to operate at
higher frequencies in order to maintain good efficiency and proper
stirring action.
INDUCTOTHERM CORP.

Another consideration is the need to keep the relatively narrow

melting channels as clean as possible. Slag may build up on the chan-
nel walls, restricting the free flow of metal and cause overheating.
Operating characteristics of this kind of furnace are constant, and
refractory lining life is good because of the constant temperature. There is an ideal relation between the size of a coreless furnace and its
operating frequency: A small furnace will yield the best results at high
Depending on the metal being melted, uppercase lining life may ex- frequencies and a large furnace works best at lower frequencies.

1 8 F O U N D RY M A N A G E M E N T & T E C H N O L O G Y | F O U N D RY M A G . C O M | J A N U A RY 2 0 2 1

Frequency vs. Size — There is always an ideal relation between
the size of a coreless furnace and its operating frequency. As a rule,
a small furnace will yield the best results at high frequencies and
a large furnace works best at the lower frequencies. There are op-
timal frequency ranges that are best suited to certain furnaces that
produce good, fast melting with a gentle stirring action. Too high or
too low frequencies are accompanied by undesirable side effects.
When a furnace is operated at a frequency lower than ideal the
result may be a violent stirring action that may produce inclusions
of slag and refractory particles, as well as gas pickup. Metal loss
may be excessive due to excess surface area of the melt and oxida-
tion of volatiles, making startup harder, and thus it may be neces-
sary to charge with greater care. Additionally, some types of scrap
cannot be used for starting.
In many cases the most important fact is that lining life can be
reduced by using too low of a frequency. On the other hand, if too
high a frequency is selected for the size of the furnace, there may be
a complete lack of stirring, uneven heating throughout the charge,
excessive side-wall temperatures and difficulty in attaining homo-
geneous melts.
The experience of stirring gained over the past several years has
been crucial for the foundry industry and those who desire high
power densities. Much of the research on furnace size and fre-
quency has been summarized in an easy-to-read chart that is very
often used to properly size induction melting equipment.
Additional Benefits — Many ferrous and nonferrous foundries
hesitate to use chips because of the possible melt contamination
and resulting poor quality due to presence of gas in the melt. With
induction melting, because of the constant temperature and excel-
lent stirring action, chips often can be used successfully and signif-
icant savings can be achieved.
One nonferrous foundry melts 300 lbs. of brass chips per heat.
Each charge of chips represents a significant savings. The plant
manager says that he collects only a small bucket of slag and dross
from seven successive heats now, in contrast to the drum-full he
J A N U A RY 2 0 2 1 | F O U N D RY M A G . C O M | F O U N D RY M A N A G E M E N T & T E C H N O L O G Y 1 9
INDUCTOTHERM CORP.
Furnace size vs. frequency for coreless induction furnaces.
collected before he installed an induction melting furnace. Another
foundry reported two weeks’ production of 75,000 lbs. resulted in
only a half drum of slag and dross.
The use of chips and other forms of metal scrap in induction
melting is growing rapidly, spurred perhaps by the trend towards
more efficient scrap handling and classification. The important
factor is that the individual pieces of the cold charge should have a
uniform composition.
Steel Foundries—Producers of steel and stainless-steel castings
must invest heavily in melting equipment, but a careful choice of
such equipment can return substantial savings.
Induction melting equipment normally requires a relatively high
grade of melting scrap, but this extra cost to an alloy steel foundry
usually is less important than to nonferrous foundries. It depends
on the alloy and the selling price of the product. If a foundry is
producing mainly carbon steel or low-alloy castings, the cost of
higher-grade scrap may be significant.
Temperature Control and Melting — Temperature control
with induction melting is accurate and rapid. Applying indirect
power for only a minute or two will increase temperature 100°F.
There’s little chance that carbon pickup will get out of hand, reduc-
ing the number of melt analyses.
The stirring action in a properly sized induction furnace pro-
duces a homogeneous melt without gas pickup, refractory inclu-
sions or alloy loss. Melting times can and should be exceedingly
fast. Typical recommended melting times for iron are as follows:
300-500 lbs. in about 22 minutes; 750 lbs. in about 27 minutes;
1,000 lbs. in about 36 minutes. As a rule, it pays to avoid melting
times exceeding 1 hour for any melt less than 4,000 lbs. For larger
furnaces, you may want to contact an induction equipment supplier
for the most accurate melt times, as these may vary according to
alloys and furnace sizes.
Michael Fanz-Huster is a District Manager for Inductotherm
Corp. Contact him at mfanz-huster@inductotherm.com, or visit
www.inductotherm.com
Pouring

Advantages of
Collapsible Breaker Cores
The steady demand for thin-walled, complex castings prompted the development of feeders
with a patented collapsible metal breaker core design, now improved based on the experience of
spot-feeding in high-pressure molding lines.
Christof Volks

C
asting buyers continue to demand cast parts with thinner development adopted the advantages of spot feeders with collapsible
wall sections and more complex designs, which requires metal breaker cores, such as consistent knock-off areas, constant
foundries to produce castings with more isolated sections feeder volume, and excellent molding results. The new design made
— and as a result they are required to adopt spot-feeding practices. it possible to reduce the breaker core metal wall section, whereas
There has been incremental development and optimization these were still suitable for the use in high pressure molding appli-
of the ram-up sleeve application cations. Also, the design was modified
technology using a patented, col- from a stepped to a grooved design.
lapsible metal breaker core de- The new sleeve concept allowed
sign. The latest development is the combination of the metal breaker
the result of applying experience core with the feeder sleeve, without
gained in the area of spot feeding applying hot glue in a press fit oper-
on high-pressure molding lines. ation. The breaker core itself rests on
In the past 40 years the devel- a small socket in the opening of the
opment of spot-feeding concepts feeder sleeve. During molding the
was driven by foundries’ indi- Foseco’s range of spot feeder products with collapsible breaker grooved part of the metal core is com-
vidual technical requirements. cores. pacted and the main feeder sleeve
Changes in the production process body moves down toward the pattern
of foundries resulting for example plate, compacting the mold sand be-
in higher molding pressures had tween sleeve and pattern plate.
to be covered with adapted spot After full compaction the major
feeder sleeve designs. part of the metal breaker core is su-
Process cost pressure and in- per-heated by the high exothermic
creasingly complex casting de- sleeve material. As a result, the metal
signs demanded by the customers neck surface in direct contact to the
influenced the market for reduced mold sand is reduced by 50% com-
A commercial application of the FEEDEX VAK demonstrating the
feeder contact and footprint areas. benefit of its small footprint. pared to the prior stepped design.
As a result, solutions were devel- Several field trials proved an
oped to achieve the lowest fettling and cleaning costs, in combi- equivalent or even better feeder neck pass-through performance
nation with optimized yield. compared to the existing concept with similar knock-off results.
Development of collapsible breaker core. In 2004 a new Today, FEEDEX VAK is a solution that is used in a high num-
generation of spot feeders was launched, which addressed the ber of iron casting applications.
foundries’ demands. The concept of a collapsible metal breaker The concept of collapsible metal breaker cores provides sev-
core provides two key advantages: eral critical advantages, such as consistent molding results even
The molding pressure is partly absorbed by the collapse of the with highest molding pressures, as well as reduced footprint and
metal breaker core and compaction of the molding sand beneath neck contact areas.
it, enabling this concept to withstand higher molding pressures Further developments have resulting in an improved design
than other conventional solutions. that provides excellent feeder neck pass-through characteristics.
The feeder neck height is reduced during molding, helping to en- An extensive test program and field trials confirmed the technical
sure that the feeder neck remains open until after the casting solidifies. validity of this concept.
In the last 15 years this feeder sleeve product range has proven Christof Volks is Foseco‘s international marketing manager for
to be a robust solution for many different foundries. feeding systems. Contact him at christof.volks@vesuvius.com , or
Latest spot feeder development. Beginning in 2015, a further visit www.foseco.com

2 0 F O U N D RY M A N A G E M E N T & T E C H N O L O G Y | F O U N D RY M A G . C O M | J A N U A RY 2 0 2 1
Autonomous Engineering does not stop
at “good enough” it stops at “optimal”.
The best solutions, right from the start.

made by Committed to casting excellence. www.magmasoft.com

Melting
Global Impact of Redux Fluxes to
Reduce Slag Build-up
Newly engineered fluxes can extend refractory life in coreless induction furnaces, prolong ladle
service life of pouring ladles, and significantly reduce slag and/or dross.
Dr. R. L. (Rod) Naro and D. C. Williams
D
uring the past 40 years, the melting methods and associated
molten metal-handling systems used by U.S. foundries have
changed significantly. Further, the quality of metallic scrap
and other iron-unit feed stocks has steadily deteriorated. The result:
Increased slag generation and slag related melting problems have
become widespread issues in recent years. A Figure 1
search of the foundry technical literature about
slag control and build-up from the past 40 years
finds only a handful of articles.
Because most iron foundries use silica-based
refractories in their induction melting operation,
they have been reluctant to add fluxes. Fluxes
are used extensively in the basic steel indus-
try, where the use is considered a science. For
foundries, however, historically there has been a
reluctance to use fluxes.
Improper use of fluxes can rapidly erode
refractory furnace linings, especially
if potent fluxes are used. More often, Figure 2
an operator error causes problems with
fluxes. The saying of “if a little works
well, then a lot should work better”
doesn’t necessarily apply. Doubling or
tripling the amount of recommended
flux additions can reduce lining life,
especially with highly reactive fluxes.
Meanwhile, refractory suppliers have
convinced foundrymen that any use will
greatly reduce refractory life, often without having any knowledge of
the chemistry or potency of the flux.
Now, newly engineered fluxes can extend the refractory life of
coreless induction furnaces by as much as 60%, extend the service
life of pouring ladles, and significantly reduce the incidence of casting
slag and/or dross inclusions.
The formation of slags in the melting of ferrous metals in the
foundry is inevitable. The composition of slag varies with the process
used and the type of iron or steel being melted. The cleanliness of the
metallic charge, often consisting of sand-encrusted gates and risers
from the casting process, or rust and dirt encrusted scrap, significantly
affects the type of slag formed during the melting operation.
Additional oxides or nonmetallic compounds also can be
formed when liquid metal is treated with materials to remove
impurities (deoxidation) or to change the chemistry of the system
(inoculation and nodulizing). Because these oxides and non-me-
2 2 F O U N D RY M A N A G E M E N T & T E C H N O L O G Y | F O U N D RY M A G . C O M | J A N U A RY 2 0 2 1
tallics are not soluble in iron, they float in the liquid metal as an
emulsion. This emulsion of slag particles remains stable if the
molten iron is continuously agitated, as in the case of the magnetic
stirring inherent to induction melting.
When used with each charge of scrap, a properly engineered flux
will cleanse the metal by flushing microscopic,
emulsified slag particles out of the melt and
assisting in the flotation to the molten metal
surface, where the slag must be removed. Re-
dux flux additions will prevent slag deposits
on the sidewalls by removing these emulsified
non-metallics. The formation of build-up on
refractory walls is a classical nucleation and
growth process. Shortly after the first liqui-
fied slag phases precipitate as a thin solid film
or substrate on a refractory surface, build-up
proceeds quite rapidly. Then, the liquified slag
phases can easily grow on the deposited
build-up since the initial build-up phase
is crystallographically similar to the liq-
uid glass phase attempting to come out
of solution. Thus, preventing this first
initial build-up is imperative in extend-
ing the refractory life.
For foundries operating induction
melting and pouring systems there has
long been a negative association with
the use of fluxes for ferrous metal pro-
duction. Silica-based refractories commonly used in induction
furnaces, are prone to chemical attack from fluxes. In many ferrous
melt shops, it’s common to add mixtures of lime/fluorspar (CaCO3/
CaF2), for desulphurization, phosphorus reduction, deoxidation,
coke cleansing, or to improve metal cleanliness. Many of these
melting furnaces might have been removed from service prema-
turely because of the inability to remove stubborn slag and insoluble
build-up effectively and safely from the sidewalls. However, recent
changes in flux formulations, eliminating chlorides and fluorides,
have achieved successes in induction melting and pouring opera-
tions while being environmental conscious.
Figure 1 is a typical example of what frequently happens when
poor quality, dirty, sand-encrusted charge materials are used.
This type of build-up was typically observed at International
Foundry A is shown in Figure 2.
Foundry A is a large producer of gray-iron automotive castings.
Some of the items produced are differential
housings and three-cylinder engine blocks.
Melting is accomplished in a seven-metric
ton coreless induction furnace.
Foundry A’s 7-metric ton charge con-
sists of 56% steel, 10% pig iron, and 34%
foundry returns. The coreless induction fur-
nace is lined with a silica refractory. Tapping
temperature from the furnace is 2,789oF
(1,532oF.) Slag build-up has been a recurring
problem for Foundry A.
The build-up caused increased melting
costs from the additional electrical require-
ments, reduced furnace capacity, loss of
melting production, and damage to refractory
walls from chipping and descaling. To elim-
inate these issues, Foundry A tested a rela-
tively new, non-fluoride flux, Redux EF40L.
For the initial trials of Redux EF40L,
0.05% Redux EF40L (7.7 lbs. or 3.5 kgs )
was added to the furnace in two increments.
Half of the Redux flux addition was added
once the initial 50% of the charge was
melted, and the remaining Redux was added
in the next back charge.
After just one Redux addition, a signifi-
cant amount of slag adhering to the furnace
refractory was removed simply by skim-
ming it from the surface. After two more
treatments, all remaining adhering slag was
removed and the furnace walls were clean,
as shown in Figure 3. The overall positive
impact of the three Redux EF40L flux treat-
ments appeared to remove all slag build-up
and return the furnace capacity to 100%.
Eliminating slag build-up from the fur-
nace walls has resulted in the following
benefits:
• Using Redux EF40 has reduced “bridging”
tendencies due to cleaner refractory walls
• Reduced power consumption during each
melt
• Hourly maintenance from scraping was
greatly reduced
• Consistent furnace capacities and charge
weights
• Improved “electrical coupling” was ob-
served with improved temperature control
• No adverse effects on the dry vibratable
silica refractory linings
Worldwide use of Redux EF40L has
shown it to be acceptable for reducing slag
viscosity and eliminating slag build-up
in coreless and vertical channel induc-
tion furnaces, pressure pour furnaces, and
ladles, while having no negative effect
J A N U A RY 2 0 2 1 | F O U N D RY M A G . C O M | F O U N D RY M A N A G E M E N T & T E C H N O L O G Y 2 3
Figure 3 melting furnaces, while preventing insolu-
ble build-up deposition. There are multiple
case histories of success in coreless induction
furnaces, channel induction furnaces, press
pouring furnaces, and ladle applications.
Now, iron foundries do not need to fear using
fluxes; they just need to use them properly, as
prescribed by the manufacturer.
on silica-based refractories when used as
prescribed. Rod Naro is president and CEO, and David
Currently, mild fluxes like Redux EF40 C. Williams is v.p. - Technology of ASI Inter-
can increase service life of ferrous induction national Ltd. Visit www.asi-alloys.com
ALL CASTING
SIMULATION
SOFTWARE IS
Cutting planes
THE SAME…
RIGHT?
find internal problems
WRONG
Finite Solutions Inc has spent over
35 years developing the world’s
CFD-based fluid flow analysis most PRACTICAL simulation
solution.
We use simulation to help CREATE an
effective rigging system, not just to
test an existing design. Results from
an unrigged simulation of the casting
are used directly to design efficient
gating and risering, both for shrinking
Feeding zone analysis
alloys and for graphitic irons. Methods
are confirmed using CFD-based fluid
flow analysis and combined
ƒ ALL Site Licenses thermal/volumetric solidification
ƒ Easiest to Use calculations. We provide the most
accurate analysis, in the least amount
ƒ Integrated Gating/Riser of time, all at the lowest cost!
Design
Want to learn more? Contact
ƒ Lowest Cost to Buy
and Use
Dave Schmidt
ƒ Combined Finite Solutions Inc
Thermal/Volumetric Tel 262.644.0785
Calculations Dave@finitesolutions.com
THE PRACTICAL SIMULATION SOLUTION https://finite.solutions
Pouring
Larger Automotive Castings Drive Innovation in
Molten Metal Delivery
Automotive design trends are fulfilling long-standing cost and safety objectives in auto
production – which is guiding further advances in casting processes.
Jeff Keller
O
ne of the most rewarding aspects of working in the
foundry industry is the rapid pace of change and the
introduction of new ideas and technology. It may not
appear this way as we observe “metalcasting” from a higher level,
but as we study the design and innovation laboratories at the many
companies that comprise this sector, we can see how the incentive
to develop new and better ideas is always present.
Most of these ideas take a considerable amount
It’s always
of time and resources to develop, and so often exciting to
“new” ideas have been a long time in the making.
Some of the exciting new trends in automotive observe new
casting are evidence of this process and will lead trends as they
to significant changes in the coming years.
Larger, multi-functional cast parts. Concern- respond to
ing automobile manufacturing, in recent years
we have seen fairly significant developments
market forces
in metal processing and the overall assembly and shape the
process. Examples are the rapid shift from steel
to aluminum body panels, and the creation of future of our
closed-loop systems in which alloys can be recy- industry.
cled and repurposed for a consistent application,
almost infinitely. The drivers here are not new: weight savings
result in higher fuel efficiency, cost effective alloys can lower cost
and recyclable materials can reduce carbon footprint.
Likewise, automotive designers’ shift toward larger structural
cast parts is not prompted by new change drivers but is resulting
in benefits to new vehicles. One primary driver is the determi-
nation to reduce the total number of parts needed for vehicle
assembly and the simplification and cost reduction this can gen-
erate. In the case described here, over 70 parts were eliminated
from the overall assembly.
Another driver is the ability to combine a vehicle’s structural
requirements with its power plant so that the battery adds struc-
tural rigidity to the frame, improving overall safety and ride
characteristics and lowering the center of mass. Advances like
these require the entire supply chain to reimagine the way cars
are made and to develop new products and processes that enable
these benefits to be achieved.
Molten metal delivery evolves. Molten Metal Equipment
Innovations has been evolving with this trend to meet the new
requirements. We have been involved with an exciting new proj-
ect at a large, California-based OEM of electric vehicles. The
2 4 F O U N D RY M A N A G E M E N T & T E C H N O L O G Y | F O U N D RY M A G . C O M | J A N U A RY 2 0 2 1
sizes of the castings they now need to produce has required a
new paradigm in which to address the new requirements.
The size of the dose is the first new reality, requiring that 105 kgs
of molten aluminum be delivered in each shot. This is more than a
robotic dipper or pressure pour technology can deliver and instead
the solution requires a pump that can deliver this amount of metal to
the diecasting machine.
The availability of metal is crucial too, and
so the technology must include a continu-
ous information loop to ensure that the metal
level remains constant. A second MMEI pump
equipped with our SMART technology is used
to measure the biscuit after each dose so that
the precise amount of metal is available to the
machine to ensure that each dose is consistent
with what is needed.
The speed of the machine cycle is another
new process requirement in that these large, ac-
curate doses must be delivered in less than 9 sec-
onds, requiring rapid metal movement without
creating turbulence and other porosity creating
opportunities. In testing we were able to get down to 4 seconds
delivery time, and now in production 7-8 seconds is the rate.
Metal temperature also is a critical requirement in the system.
MMEI, working with our partner Advanced Systems & Inte-
gration, uses proprietary heated-launder piping that maintains
constant metal temperature throughout the process. We also
incorporated a rotary degasser into the system to ensure the
highest degree of metal quality and to prevent any porosity from
getting into the part.
It’s always exciting to observe new trends as they respond to
market forces and shape the future of our industry. They keep us
all on our toes, and lead to some long days and late nights. This
is healthy and supports new investment in the development of
new materials, processes, and ultimately in new products. In our
case, it has been exhilarating to work on a challenge that caused
us to leave our comfort zone and branch out into some new ar-
eas. Even more, it is exciting to think about where this will take
the industry and how these new trends are the collective output
of all of us coming together to support new ideas.
Jeff Keller is chairman and CEO of Molten Metal Equipment In-
novations. Contact him at LinkedIn, or visit www.mmei-inc.com.
Digital Dosing Optimizes
Aluminum Diecasting
Alupress is operating a pilot program for real-time reporting of
sensor data to monitor furnace fill levels, with analysis-based
indicators to time, alloy, and volume requirements.

The digital dashboards can be accessed in the melt shop and are displayed on a dedicated monitor.
Forklift operators transferring liquid metal from furnaces to the diecasting machines have secure
access to this real-time data via a tablet, to ensure optimal fill levels are maintained.

A
ddressing high-volume demand for
automotive aluminum diecastings
is more than a logistical or techno-
logical challenge: it’s a data-management
issue, and now an automotive aluminum
diecaster is piloting a data-driven technol-
ogy package to improve productivity at its
plant in Hildburghausen, Germany.
Alupress, which also has operations in
the U.S. and Italy, has adopted the Mo-
nitizer® | Refill Monitor to optimize the
supply of molten aluminum to its dosing
furnaces. Developed by StrikoWestofen
in partnership with the Norican group’s
in-house digital lab, the process control
package uses sensor data to check furnace
fill levels continuously against the metal
consumption of the diecasting process.
Then, it presents the analyzed data as in-
formative online dashboards that show
clearly, in real time, when each furnace
will need refilling, with which alloy and
how much metal will be required.
“When we heard about Monitizer |
Refill Monitor we could see it offered an
innovative solution to a number of practi-
cal challenges we face,” explained Enrico
Sonnefeld, head of maintenance at Alu-
press Hildburghausen.
“Our melting furnaces are located quite
a distance from our diecasting halls. To ac-
curately check the real-time fill levels of our
32 dosing furnaces takes time, and the logis-
tics involved mean there is always a risk of
refilling with the wrong alloy, overfilling, or
underfilling. As well as being unproductive,
these factors can also result in undesirable
stop/starts, for instance if melt is not ready,
downtime and also problems further down
the line with casting quality – in particular if
fill levels have dropped too low.”
As part of the pilot program, eight of

J A N U A RY 2 0 2 1 | F O U N D RY M A G . C O M | F O U N D RY M A N A G E M E N T & T E C H N O L O G Y 2 5
 Pouring

Alupress’ dosing furnaces have been connected to the Mo- An example the Monitizer® | Refill Monitor digital dashboard for eight
furnaces at Alupress in Hildburghausen, Germany.
nitizer | Refill Monitor solution, including five StrikoWestofen
Westomat furnaces and three from another furnace supplier. tion mechanism used is supplier agnostic, we can connect any
“This was actually one of the things that impressed us about of our furnaces to Monitizer | Refill Monitor. We also didn’t
this innovation,” Sonnefeld added, “because the data collec- need to have any pre-existing digital infrastructure or IIoT
experience.”
A noteworthy feature of the system is that the dashboards
are completely customizable, to show at a glance the informa-
tion that is going to be most valuable to the particular foundry.
This includes setting color codes – green, amber, red – to in-
COMPLETE TURN-KEY ENGINEERED CONVEYOR SYSTEMS dicate priority actions required. The level of customization is
ENGINEERING MANUFACTURING INSTALLATION something already has been advantageous to Alupress.
StrikoWestofen development engineer Florian Kulawik
reported: “Alupress has configured its dashboards to display
overall furnace fill level as a percentage, and also the exact
time left until the furnace is at 40% capacity, as refilling before
this point produces optimal results in terms of melt quality and
for continuous production.”
He continued: “Clear, color-coded indicators change as the
threshold is reached. The dashboards can be accessed in the melt
shop and are displayed on a dedicated monitor in the production
hall. The forklift operators responsible for transferring the liquid
metal from the melting furnace to the production hall also have
securely authorized access to this real-time data via a tablet in
the vehicle, to ensure optimal fill levels are maintained.”
The pilot project is ongoing but Alupress already has seen
the benefits of real-time data monitoring. “Since the solution
WEBB-STILES offers more than 64 years of practical expertise in the Overhead was installed our dosing furnaces have been in continuous use
Conveyor and Custom Engineered Conveyor Systems.
because at any single point in time, we can see what’s needed
Whether you are looking for a new system or having problems with a current
system, contact a WEBB-STILES Sales Engineer for all your conveyor needs. to optimize the process,” Sonnefeld noted. “What’s more,
because the solution is completely scalable, we know it will
Corporate Webb-Stiles of Alabama
Sales / Engineering / Manufacturing Sales / Engineering / Manufacturing be an easy job to expand the number of furnaces, old or new,
Valley City, Ohio Gadsden, Alabama connected as and when required.”
Ph: 330-225-7761 Ph: 256-492-6642
Learn more at www.strikowestofen.com
sales@webb-stiles.com www.webb-stiles.com

2 6 F O U N D RY M A N A G E M E N T & T E C H N O L O G Y | F O U N D RY M A G . C O M | J A N U A RY 2 0 2 1
 GREENSAND CONTROLS PROVIDES A COMPLETE
LINE OF GREEN SAND PREPARATION AND PROCESS
CONTROL EQUIPMENT.

´*5((16$1'(;3(57μ02'(/(7$
´$%&μ$8720$7,&%(1721,7(
CONTROL SYSTEM: Provides Primary
Compactability control while providing
additional supervisory control of system
bentonite and green strength levels

´*5((16$1'(;3(57μ02'(/
AUTOMATIC COMPACTABILITY
CONTROLLER: Provides primary
compactability control for sand systems
that experience minimal variations in
bentonite and green strength levels

´*5((16$1'(;3(57μ&21752/6<67(06$'9$17$*(6
x RUGGED DESIGN, BUILT TO LAST IN THE FOUNDRY
x SINGLE STATION TESTING
x COMPACTABILITY AND GREEN STRENGTH TEST AT SAME POSITION
x NO INTERMEDIATE POSITION STOP REQUIRED
x INNOVATIVE BENTONITE CONTROLS
x DISTRIBUTED I/O CONTROL DESIGN AVAILABLE
x HIGH PERFORMANCE ADAPTIVE CONTROL LOGIC INCLUDED
x NO OPERATOR REQUIRED
x SIMPLE INTUITIVE OPERATOR INTERFACE
x COMPREHENSIVE ALARMS AND DIAGNOSTICS
Shakeout

A New Approach to
Sand Reclamation
An innovative, small-footprint attrition mill offers foundries a cost-effective, customizable,
and reliable route to recovering sand and metal from waste streams.
Mark M. Didion
other offerings, providing a fast
project payback.
The goal of the new develop-
ment was to make a machine that is
so affordable that sand reclamation
becomes a no-brainer. BRUTUS is
loyal to the bottom line and loves to
please owners.
The orbital action process is ex-
tremely efficient, and the savings
already listed will easily cover the
low-energy requirements. The waste
sand is scrubbed and screened twice
prior to discharge. The metal is sep-
arated from the sand and thoroughly
cleaned.
With other attrition mills cur-
The new attrition mill addresses smaller foundries’
rently available to the foundry mar-
need for a vibratory system to reduce chemically- ket, the metal discharge process
bonded sand chunks down to grain size, and is laborious. Conveyor Dynam-
separate and clean metal in those waste streams.

N
umerous inquiries from smaller foundries revealed
a glaring need for an affordable vibratory sys-
tem to reclaim no-bake and core sand waste
streams. These foundries needed a unit that could re-
ceive their chemically-bonded sand chunks and reduce
these down to grain size, as well as separate the metal
contained in those waste streams. Additionally, they needed
this machine to work effectively in a small footprint. This led
Conveyor Dynamics Corp. to develop its latest innovation -
BRUTUS.
The name came to be applied after the new machine was
fully developed. It’s a reflection of the character of the
unit: tank-like, compact, and voracious – bringing to mind
a tenacious bulldog to mind. BRUTUS devours hard sand
lumps and like a loyal dog is the “foundry’s best friend,”
specifically built to be at home in tough environments.
BRUTUS is ideally suited to foundries with lower ton-
nage requirements that understand the immediate benefits
of reclaiming waste sand. The savings accrued by reducing
new sand purchases while avoiding disposal costs, labor
costs, trucking expenses, and tipping fees add up quickly.
These savings are captured immediately by installing the
new machine, and with an attractive price compared to
ics’ simple and efficient design
discharges the metal and debris
effortlessly.
BRUTUS is accommodating
and can easily be tailored to fit a
foundry’s specific layout. The
reclaimed sand spout can be designed to discharge into a
hopper, conveyor, or even directly into a bucket elevator.
Like a tough bulldog, BRUTUS is compact with a low feed
height, so a forklift with a dump hopper, a front-end loader,
or conveyor can feed it easily. A load/storage hopper can
be added to hold even more sand chunks, to keep BRUTUS
constantly fed.
The innovative design is quite clever and delivers
exceptional performance that is easy to maintain. Con-
veyor Dynamics Corp. is well known for their larger
systems and have been perfecting vibratory equipment
for 25 years with developments based on user experi-
ence. The innovative attrition mill available now gives
foundries an affordable, compact option for reclaiming
no-bake and core sand waste streams.
Contact Mark Didion for more information, or visit Conveyor
Dynamics at www.conveyordynamicscorp.com

2 8 F O U N D RY M A N A G E M E N T & T E C H N O L O G Y | F O U N D RY M A G . C O M | J A N U A RY 2 0 2 1
Casting Finishing

How Vacuum Impregnation Supports

Environmental Responsibility
Automotive casting production calls for aggressive efforts to eliminate waste and conserve resources,
and manufacturers need to make their processes cleaner, safer, and more resource-efficient.
Andy Marin

A
utomotive manufacturers recognize that operating with prac- 1. Enabling design freedom. To make parts lighter, casting design
tices and technologies that are environmentally responsible engineers specify aluminum alloys and thinner walls for critical com-
and profitable are not mutually exclusive. Being environmen- ponents. Meanwhile, in order to achieve new design standards, these
tally responsible can achieve better growth, cost savings, improve components have higher performance requirements and lower ac-
brand recognition, and increase profit- ceptable leak rates. These tighter require-
ability. The environmental impact of the ments result in more parts being rejected
responsible use of resources is beneficial and scrapped due to diecasting porosity.
to everyone, and automotive manufac- Vacuum impregnation allows engi-
turers play a leading role. neers to specify thinner, lighter designs
Examples of manufacturers being while meeting quality standards without
environmentally conscious occur in all concern over the effects of porosity. The
channels of the automotive supply chain. Whether it’s caused by shrinkage, cold shuts, inclusion, design freedom allows the engineers to
or entrapped gasses, porosity is inherent to the casting
For example: process. Interconnected porosity leads to defects, which develop better-performing and fuel-effi-
- Ford’s closed-loop recycling manu- are the leading cause of waste and scrap. This waste cient vehicles.
increases the carbon footprint of the casting process.
facturing process. The OEM recovers 2. Maximizing part usage. Porosity
enough aluminum scraps each month to in castings robs manufacturers of the
produce more than 37,000 new Ford 150 opportunity to move 100% of their
truck bodies, all while consuming fewer parts into production. A 15% “fall
natural resources and lowering energy out” of manufactured parts means that
consumption. 15% more aluminum castings will be
- Aluminum diecasting manufacturers scrapped, and profits will be erased. The
are reducing their carbon footprint by Vacuum impregnation seals leak paths that form during vacuum impregnation process allows
adopting “green” aluminum. Green casting without changing a casting’s dimensional or manufacturers to use castings that oth-
functional characteristics.
aluminum is manufactured using less erwise would have been scrapped.
carbon-intensive hydropower rather than carbon-intensive fossil 3. Eliminating melting and re-manufacturing. Vacuum
fuels. Making one metric ton of aluminum with hydropower releases impregnation eliminates the costly melting and re-smelting of
approximately two metric tons of CO2 equivalent, while making one material to manufacturer replacement castings. Vacuum impreg-
metric ton of aluminum with fossil fuels releases up to 18 metric tons nation also removes all the carbon and waste costs associated with
of CO2 equivalent. trimming, blasting, machining, testing, and washing of replace-
Automakers and their casting suppliers can reduce waste and ment parts.
conserve resources further by implementing vacuum impregnation to Each of these factors represents an opportunity to minimize waste,
correct casting porosity and surface defects. improve a manufacturer’s profitability, and positively impact the
Porosity. Whether it’s caused by shrinkage, cold shuts, inclusion, or environment.
entrapped gasses, porosity is inherent to the casting process. Intercon- Automotive manufacturers and their suppliers must continue
nected porosity leads to defects, which are the leading cause of waste to be aggressive in their efforts to eliminate waste and conserve
and scrap in casting production. This waste increases the carbon resources, in order to compete now and to grow their enterprises. In
footprint of the casting process. that light, manufacturers should look for other opportunities in their
Vacuum impregnation. Vacuum impregnation is a low-impact production processes to be cleaner, safer, and make more efficient
method of sealing leak paths that form during the casting process. use of resources. One of those opportunities is vacuum impregnation.
Specifically, vacuum impregnation seals the internal, interconnecting It assists manufacturers to reduce production waste dramatically
path of porosity that breaches the casting wall and may result in prod- and control their resources by returning nearly 100% of parts to the
uct failure. The technique seals the porosity without changing the production line.
casting’s dimensional or functional characteristics. Andy Marin is the marketing coordinator for Godfrey & Wing, a
Although there are many ways that vacuum impregnation aids man- developer of vacuum impregnation technology. Contact him at
ufacturers’ efforts to be environmentally conscious, three stand out: amarin@godfreywing.com, or visit www.godfreywing.com

J A N U A RY 2 0 2 1 | F O U N D RY M A G . C O M | F O U N D RY M A N A G E M E N T & T E C H N O L O G Y 2 9
Information Technology

Designing Feeding Systems

for Investment Castings
In just a few minutes, simulation software can indicate gate and feeder-bar sizes, and gates can
be positioned to provide feed metal to the recommended areas of the prospective casting.
David C. Schmidt
he guidelines for foundries designing rigging for sand gate contact points.
T castings have been available for quite some time — and
are well accepted. These rules can be adapted and used suc-
Gate and feeder-bar sizes for each feeding zone are
calculated using variations on the well-known “Modulus
cessfully to rig castings made by investment casting, too. technique.” While the Modulus is a geometric calculation
When combined with casting simulation software, effec- (Volume/Surface Area), solidification time information
tively rigging investment castings to produce sound parts is a from the simulation is converted into a “Thermal Mod-
fast and repeatable process. Here’s how: ulus.” This takes into account not only casting alloy and
The design process. The general design process consists of shell material, but also the solidification dynamics of the
these four steps: specific situation,
1. Simulation of the including use of in-
‘naked’ casting. sulating materials
2. Gate sizing and such as Kaowool or
feeding design. Fiberfrax wrapping.
3. Rigging geometry These are guide-
creation. lines for gate and
4. Verification via STL model of a step block casting. ‘Naked’ simulation results, without filling.
feeder bar sizing
CFD/solidification • From the Riser
simulation. Design Wizard, cal-
The first step in the culate the maximum
rigging process is to modulus of the feed-
run a simulation of ing zone.
the part ‘naked’; i.e., • The 2D modulus of
without any rigging the casting end of the
system. Simulation gate will be equal to
results show the ef- Tapered gate and feeder bar added to the Simulation of rigged model, showing feeding the maximum mod-
fects of the part ge- casting model. from the bar is adequate for a shrink-free ulus.
casting.
ometry on the overall • The 2D modulus of
solidification. In this simulation, filling analysis typically the feeder-bar end of the gate will be 1.2-times the maxi-
is not done, which provides extremely rapid results and can mum modulus.
point out preferred gate locations that will promote directional • The 2D modulus of the feeder bar also will be 1.2-times the
solidification. maximum modulus.
All that is required for the initial simulation is a casting • For the square cross-section, the modulus is the edge
model, normally provided by the customer in STL file format, length/4.
plus the basic process details, such as casting alloy, shell ma- Once we know the maximum modulus in the casting or
terial, pouring temperature, and shell pre-heat temperature. the feeding zone, we can calculate the appropriate size for a
Gate and feeder-bar design. The data from the un-rigged tapered gate, as well as feeder-bar dimensions that will ade-
simulation can be used to design the rigging components. quately feed that part of the casting. This is done in the Riser
Typically, the gates are designed first, followed by the feeder Design Wizard, which was designed originally to calculate
bar. The software uses the progression of solidification, along cylindrical risers for the sand casting process. However, it
with a pattern recognition algorithm, to determine the separate provides good information for investment castings, too.
feeding paths on the casting. The software can find the last An example of the wizard screen shows the modulus cal-
points to freeze on each feeding path, which are the preferred culations used to size both the tapered gate and the feeder bar.

3 0 F O U N D RY M A N A G E M E N T & T E C H N O L O G Y | F O U N D RY M A G . C O M | J A N U A RY 2 0 2 1
Modeling the rigging system. Gate and feeder-bar calcu-
lations normally take only a few minutes to perform. Rigging
components can be created in CAD or in the simulation soft-
ware itself. Items that will be used for more than one casting,
such as a standard size of pouring cup, can be created in a
component format, and re-used as needed, thereby saving con-
siderable time in the model creation phase.
If a library of gating components is developed and used
the entire rigging design process, from loading the unrigged
Using Virtual Reality in
Metalcasting Environments
AR/VR technologies are helping manufacturers to increase their digital transformation — and emerg-
ing as the major change agent for production layouts, custom equipment development, and training.
David W. White
One frame of a Virtual Reality display for a new electric melting furnace.
M
ost people have experienced or at least heard of virtual
reality for gaming, but still are surprised at how the
technology has caught on in manufacturing applica-
tions. Some tech industry analysts project that the combined
augmented reality (AR) and virtual reality (VR) market will
register growth in the billions of dollars for equipment demon-
stration, inspection, training (especially safety), process man-
ufacturing and maintenance. AR/VR technologies are helping
manufacturers to increase their digital transformation efforts,
and they are emerging as the major change agent for many man-
ufacturing sectors. Metalcasters surely will be included.
The hardware and development time necessary to adopt these
technologies has decreased significantly over the past few years,
making VR very affordable options for any manufacturer. The
J A N U A RY 2 0 2 1 | F O U N D RY M A G . C O M | F O U N D RY M A N A G E M E N T & T E C H N O L O G Y 3 1
model to having a fully rigged geometry ready for verification
simulation, can be as short as 30 minutes or so.
While investment casting can be more time-intensive than
many sand casting sequences, casting simulation software can
help those foundries produce high-value components quickly
and repeatably.
David Schmidt is the vice president of Finite Solutions Inc.
Contact him at dave@finitesolutions.com, or learn more at
https://finite.solutions
manufacturing benefits of using VR include:
• Demonstrating equipment, to explain heavy, bulky and danger-
ous equipment safely.
• Designing production floors, to ensure the design is correct for
your plant, operators, and processes.
• Simulating production processes, to verify cycle times and
production rates.
• Inspecting equipment designs, to verify custom equipment be-
fore steel is fabricated and controls are programmed.
• Safety, operational, and maintenance training, to safely train op-
erators how to clean, operate and maintain dangerous equipment.
• Attracting talent.
1. Demonstrating equipment. We can demonstrate so
much more in VR than we ever could with 2D or 3D draw-
ings. With VR, customers can easily inspect and manipulate
a 3D image to show all sides and underneath the unit, to see
how it works from the inside. That cannot be done with vid-
eos, photographs, or drawings.
Additionally, we have added VR models to our website for po-
tential customers to view them—all over the world. We showed
our furnace VR to the major electric car manufacturer and ended
up getting a contract to build several new furnaces there. When
your customers realize you are on the cutting edge of technology,
they are eager to work with you. We credit much of our increase
in sales because of this capability.
At tradeshows, instead of shipping heavy equipment (at major
expense) I just bring VR equipment. For a fraction of the shipping
cost I am able to show customers just about any furnace type we
build. We no longer need to arrive at the event two days early to
set up the booth. The cost of everything more than paid for itself
Information Technology
the very first show.
2. Designing production floors. Think about having the
ability to show potential customers their plant layout in VR.
It looks clean, well-managed, and operators can review it for
accuracy and functionality, meaning how material will move
through the production floor. Seeing their improved operat-
ing in VR can reveal potential problems that may not be no-
ticed in a traditional drawing. Identifying potential problems
before floors are poured and metal is fabricated can save a
foundry thousands of dollars, or even tens of thousands.
A building or factory layout can be assembled rapidly and
modified during a collaborative session and displayed on-screen
for multiple participants, either local or networked. Users can
position machinery or components inside a virtual copy of the
foundry environment using ‘hand tracking,’ which allows users to
‘grab’ virtual objects and position them directly.
Once a layout has been assembled, users can tour and experi-
ence the design and determine if more changes are needed.
Using VR is ideal for planning new robotics or other automa-
tion equipment to an existing layout, as operators can position
machinery within a virtual copy of the foundry to ensure proper
workflow. With immersive VR you can readily review any build-
ing obstacles.
3. Simulating processes. VR provides the ability to see
your equipment in action, in your customer’s environment
^ AD INDEX
Name Page
ASK Chemicals ......................................................... IFC - 1
B & L Information Systems ............................................13
Carrier Vibrating Equipment, Inc. ....................................6
Conveyor Dynamics Corp. .......................................16, 17
Cor-Met, Inc. ...................................................................25
Didion International, Inc. .............................................8, 9
Finite Solutions, Inc. ......................................................23
Foundry Educational Foundation .................................33
Foundry Solutions & Design, LLC ....................................5
General Kinematics Corp. .............................................BC
Green Sand Controls, LLC ..............................................27
Inductotherm Corp. .....................................................IBC
Magma Foundry Technologies ......................................21
Summit Foundry Systems, Inc.........................................3
Vulcan Engineering Co. ....................................................7
Webb-Stiles Co. ..............................................................26
Every effort is made to ensure the accuracy of this index.
However, the publisher cannot be held responsible for
errors or omissions.
3 2 F O U N D RY M A N A G E M E N T & T E C H N O L O G Y | F O U N D RY M A G . C O M | J A N U A RY 2 0 2 1
to demonstrate cycle times and verify productivity. Unlike
a video, virtual reality is a medium that can demonstrate a
process in the specific location where it will be installed – an
invaluable perspective for foundry plant managers.
4. Inspecting equipment designs. Foundry equipment is
custom equipment by definition. It must meet productivity
demands as well as floorspace requirements. With VR, you
can inspect a 3D drawing to verify it’s correct for your oper-
ation. Verifying it in VR, also allows for easy changes to the
CAD, versus expensive changes to the equipment later.
5. Safety, operational, and maintenance training.
Imagine placing an 18-year-old trainee in front of an
1,800 °F furnace opening, instructing him to “clean that.”
It’s likely that employee will go to lunch and never come
back. However, put a VR headset on an employee to teach
him how to clean a furnace properly (with interactive re-
sponses) and you will have prepared him to handle one of
the hottest and toughest jobs in the plant – safely.
This type of training can be developed and implemented to
almost any job in your plant. Using VR, you can train workers
for virtually any part of your manufacturing process, to impart
principles and practices for safety, operation, troubleshooting, and
maintenance. All you need is a laptop and headset, and you can of-
fer your operators training on-demand, as you and they require it.
With the aid of VR, individuals retain more information – es-
pecially critical for dangerous environments – as workers learn
faster, retain better, and are able to experience the actual hazards
of a particular process without the risk of getting hurt. In VR, they
can learn to drive a forklift or operate machinery and understand
hazards. Furthermore, you can add testing to the training to ensure
the objectives of the course are understood.
6. Attracting talent. In addition to all of the above techni-
cal and money-saving advantages, we also have recognized
an important, manufacturing-specific benefit: enticing young
people to want to join the workforce. We have attracted sev-
eral new engineers primarily because we demonstrated our
furnace products to them using virtual reality.
Engineers coming out of universities today have been exposed
to these technologies; therefore, when you present them with
proof that you are actively using these technologies you confirm
for them that you are the right organization for them to start their
professional careers.
Furnaces are large, heavy, and complex. The Schaefer Group
uses VR regularly to demonstrate equipment, to help overseas
customers to inspect and approve their custom equipment. And,
we continue to add training modules to meet our customers’
safety and operational training needs.
You too can demonstrate equipment, layout a production floor,
verify processes, and train more effectively for less money with
the use of VR. There’s nothing preventing you from experiencing
the productivity benefits of virtual reality in your operation.
David W. White is the former national sales manager for The Schaefer
Group Inc., as well as a personnel trainer and speaker on metalcasting
technologies. Contact him at David.White@theschaefergroup.com
^
BUSINESS STAFF
MANAGEMENT & TECHNOLOGY
2 Summit Park, Suite 300 • Independence, OH 44131
Telephone: 234-466-0200
BUSINESS STAFF
medianet@ms13.hinet.net • Tel.: +886-4-2322-3633 • Fax: +886-4-3233-3646
John DiPaola • VP and Group Publisher
jdipaola@endeavorb2b.com (440) 33-6099
Joe DiNardo • Associate Publisher
jdinardo@endeavorb2b.com (440) 487-8001
Brenda Wiley • Production Manager
bwiley@endeavorb2b.com (714) 406-2661
Frank Chloupek • Director, User Marketing
fchloupek@endeavorb2b.com (909) 736-0826
Robin Slanie • Sales Support Specialist
rslanie@endeavorb2b.com
Steven Porter • Group Digital Advertising Manager
sporter@endeavorb2b.com
REPRINTS, CUSTOMER SERVICE, AND CONTENT REUSE
Reprints/Permissions • Reprints@endeavorb2b.com
National Archives (NAPC) • Microfilm Copies
Tel.: 1-800-420-6272, ext. 657
SALES OFFICES
Joe DiNardo • U.S. and Canada
jdinardo@endeavorb2b.com, Tel.: (440) 487-8001
Julian Maddocks-Born, • U.K., Europe
julian@itsluk.com, Tel.: 44-1442-288299
J A N U A RY 2 0 2 1 | F O U N D RY M A G . C O M | F O U N D RY M A N A G E M E N T & T E C H N O L O G Y 3 3
Yoshinori Ikeda • Japan
Tel.: 81-3-3661-6138, Fax: 381-3-3661-6139
Cesare Casiraghi • Italy
c.casiraghi@tin.it • Tel.: 39-031-261407 • Fax: 39-031-261380
Adonis Mak • China, Hong Kong
adonism@actintl.com.hk • Tel.: +85-2-2838-6298
Charles Yang • Taiwan
ENDEAVOR BUSINESS MEDIA
Chris Ferrell • CEO
Scott Bieda • CRO
Patrick Rain • COO
June Griffin • CMO
Angela Mitchell • VP, Accounting
Jessica Klug • VP, Finance
Mike Christian • EVP, Industrial
Monique Leija • VP, Digital Business Development
Kristine Russell • EVP, Special Projects
Curt Pordes • VP, Production Operations
Glenn Scheithauer • VP, Technology
Tracy Kane • Chief Administrative and Legal Officer
Endeavor Business Media, 331 54th Ave N., Nashville, TN 37209, U.S.
www.endeavorbusinessmedia.com.
Printed in U.S.A. • Copyright © 2021 Endeavor Business Media, LLC
All Rights Reserved
FOUNDRY MANAGEMENT & TECHNOLOGY is indexed in the Applied Sciences and
Technology Index and with the Engineering Index generally available in libraries. Copying:
Permission is registered with the Copyright Clearance Center Inc. to photocopy any
article, with the exception of those for which separate ownership is indicated on the first
page of the article, for a base fee of $1.25 per CCC. (Code No. 0360-8999/97 $1.25 + $.60)
 Opening for Foundry Project Engineers and Project Managers
Foundry Solutions & Design Company (FS&D) is a 20 year old rapidly growing international
foundry engineering design and consulting company headquartered near Atlanta, GA.

Due to its growth, the company is wishing to extend its project engineering and project
management team and is seeking motivated, self-starters who have a background in the
foundry industry, including experience in budgeting, scheduling, cost control and the ability
to complete projects on time and in budget.

The candidates would ideally possess the following:

x Bachelor’s Degree in engineering or other technical discipline
x A minimum of 5 years’ experience in the metal casting industry in increasing
responsible positions
x Excellent communication and presentation skills
x Ability to work independently in a fast paced environment
x Comfortable in dealing with top levels of management
x Proficiency in the Microsoft Office programs (Word, Excel, PowerPoint)
x Willing to travel (including internationally)

To learn more about FS&D and its activities, please visit www.foundrysd.com.

The company offers attractive compensation and benefits package.

Please e-mail resume to engineering@foundrysd.com.

3 4 F O U N D RY M A N A G E M E N T & T E C H N O L O G Y | F O U N D RY M A G . C O M | J A N U A RY 2 0 2 1
 A U TO M ATED FOUNDRY SYST E M S
Summit Foundry Systems, Ft. Wayne, IN . . . . . . . . . . . . . . . . . . . . 260-749-7740
CO N VEY OR S, BELT
Summit Foundry Systems, Ft. Wayne, IN . . . . . . . . . . . . . . . . . . . . .260-749-7740
CO N VEY OR S, P NEUMAT I C
Dynamic Air Inc., St. Paul, MN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .651-484-2900
CO N VEY OR S, V IBR ATIN G
Conveyor Dynamics Corp., St. Peters, MO. . . . . . . . . . . . . . . . . . . . .636-279-1111
General Kinematics, Crystal Lake, IL . . . . . . . . . . . . . . . . . . . . . . . .815-455-3222
CO REM AKING
D RO SS R EC LAMATION
Didion International, Inc., St. Peters, MO . . . . . . . . . . . . . . . . . . . . .636-278-8700
General Kinematics, Crystal Lake, IL . . . . . . . . . . . . . . . . . . . . . . . .815-455-3222
ELEVATOR BUCK ETS, S E L F CL E ANI NG
States Engineering Inc., Ft. Wayne, IN . . . . . . . . . . . . . . . . . . . . . . .260-747-6195
Summit Foundry Systems, Ft. Wayne, IN . . . . . . . . . . . . . . . . . . . . .260-749-7740
F O UN D RY S YS T E M S
Summit Foundry Systems, Ft. Wayne, IN . . . . . . . . . . . . . . . . . . . . . . . 260-749-7740
J A N U A RY 2 0 2 1 | F O U N D RY M A G . C O M | F O U N D RY M A N A G E M E N T & T E C H N O L O G Y 3 5
MAT E RIA L H A ND L ING E Q U IPME NT
Conveyor Dynamics Corp., St. Peters, MO. . . . . . . . . . . . . . . . . . . . . . . 636-279-1111
General Kinematics, Crystal Lake, IL . . . . . . . . . . . . . . . . . . . . . . . . . . 815-455-3222
MO L D H A ND LING E Q U IPME NT
States Engineering, Ft. Wayne, IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260-747-6195
Summit Foundry Systems, Ft. Wayne, IN . . . . . . . . . . . . . . . . . . . . . . . 260-749-7740
SA ND H A ND L ING E Q U IPME NT
General Kinematics, Crystal Lake, IL . . . . . . . . . . . . . . . . . . . . . . . . . . 815-455-3222
States Engineering, Inc., Ft. Wayne, IN . . . . . . . . . . . . . . . . . . . . . . . . . 260-747-6195
Summit Foundry Systems, Ft. Wayne, IN . . . . . . . . . . . . . . . . . . . . . . . 260-749-7740
SA ND RE CLA MAT IO N E Q U IPME NT
Didion International, Inc., St. Peters, MO . . . . . . . . . . . . . . . . . . . . . . . 636-278-8700
General Kinematics, Crystal Lake, IL . . . . . . . . . . . . . . . . . . . . . . . . . . 815-455-3222
SH A KE O U T S, RO TA RY
Didion International, Inc., St. Peters, MO . . . . . . . . . . . . . . . . . . . . . . . 636-278-8700
General Kinematics, Crystal Lake, IL . . . . . . . . . . . . . . . . . . . . . . . . . . 815-455-3222
SH A KE O U T S, VIB RAT ING
Conveyor Dynamics Corp., St. Peters, MO. . . . . . . . . . . . . . . . . . . . . . . 636-279-1111
General Kinematics, Crystal Lake, IL . . . . . . . . . . . . . . . . . . . . . . . . . . 815-455-3222
VA CU U M CLE A NING E Q U IPME NT & RE NTA L
DeMarco Industrial Vacuum Corp., Crystal Lake, IL. . . . . . . . . . . . . . . 815-344-2222
Visit our website: DeMarcoVacuums.com • Email: Sales@DeMarcoVacuums.com
VA LVE S, B U T T E RFLY
Posi-flate, St. Paul, MN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 651-484-5800
^ CLOSING COMMENT
Plan Your Message, Plan Your Schedule,
and Adapt for Success
Keeping your marketing message in front of your audience means meeting your prospects
and customers where they are, digitally and in person.
S
pring, summer, the start of school – the calendar identifies
the natural launch dates for our work and our lives, and the
clean-slate of January comes first. But the truth is, you can
start a business plan at any time, and your marketing effort should
always follow a plan.
In business, planning is knowing both what you are working with
and what you are working to-
ward. For marketing, the tool
you work with is “communi-
cation”, which answers ques-
tions -- the most important of
which are:
-Who are you talking to? (An-
swer… the audience.)
- Where will you have the con-
versation? (… Via a channel.)
- What do you want say? (…
Your message.)
These are critical questions
to kick-off your planning, but they are not the only ones to consider
when drafting a particular campaign or a full year of marketing. It is
also helpful to question and review what overall business develop-
ment activities have worked in the recent past. Reviewing your sales
activities, which naturally include the sales goals that the business
is working towards, alongside your marketing activities (what you
are working with) will lend the planning process a more integrated
business development viewpoint.
Marketing builds brands, but brands without sales are not in
business very long. Sales and marketing teams should be working
together to improve the business.
Start with marketing. What worked as a marketing initiative? What
was the most successful marketing initiative in the last 10 months?
What made it successful? How did you track that success? How was
the effectiveness measured? Incoming leads are a common metric for
marketing effectiveness? Have the team review the past 10 months’
marketing activities that generated the most leads -- both immediately
and over time. How can that activity be expanded or duplicated? What
percent of those leads resulted in sales? What steps can be taken to
increase the number of sales converted from those leads?
Sales typically are goal-driven, with ample numeric evidence.
Questions to consider for evaluating sales performance include:
What activity generated the most sales? What were some of the
reasons this activity was successful? And, how can some of those
reasons be carried over to other sales activities?
Alexandria Trusov | Marketing Executive and Strategist
3 6 F O U N D RY M A N A G E M E N T & T E C H N O L O G Y | F O U N D RY M A G . C O M | J A N U A RY 2 0 2 1
Have a combined sales and marketing team evaluate the length of
the current sales cycle per lead. (This means time engaged with staff.
The goal is to keep staff engaged at the points of the sales cycle that
are pivotal, rather than trivial.) Reviewing the current sales process, is
there something that could be done to shorten the active sales cycle?
Usually I offer pretty simple advice for planning marketing ac-
tivities and budgets: 1) Evaluate
what worked (see above) and
do more of it; 2) Stay consistent
with your plan; and 3) Add one
“stretch” item (activity, channel,
ad placement, etc. that you ha-
ven’t tried before.) Of course,
there will be nuances as you pro-
Nicoelnino | Dreamstime
ceed this way, but building on
prior success and staying consis-
tent reliably builds the branding
momentum that will lead to sales.
Covid-19 and the ensuing pan-
demic with economic repercussions might have knocked this advice
for a tailspin because consistency became difficult, if not impossible,
on some fronts. “Pivot” became the operative term as plans shifted
weekly or daily, and regular re-evaluation has become a requirement
of our current business climate. 2020 taught everyone the value of
flexibility and adapting to changes.
Applying that adaptability mindset to your 2021 marketing plan-
ning might look like…
- Repurposing part of your trade show budget into direct-mail pieces
in support of your virtual events;
- Spending unused travel budget to equip sales staff with light boxes,
so they’ll appear more personable on those Zoom sales calls;
- Creating more digital content, such as videos or how-to’s, rather
than print materials.
Despite the many other changes 2020 has brought, marketing
continues to play a role in successful businesses - a role made more
vital as the need for clear communication has become increasingly
critical. Keeping your message in front of your audience means
meeting your prospects and customers where they are, digitally and
in person. A marketing plan will help. And January is a great time
to start.
Alexandria Trusov is the Global Marketing Manager at Alpha Resources
and a B2B marketing consultant to manufacturers and other B2B
companies. Contact her at atrusov@truinsightsconsulting.com or visit
www.truinsightsconsulting.com.
Deliver more tons per hour.
Inductotherm Heavy Steel Shell Furnaces, when combined with our advanced VIP ®
power
supplies, will increase your throughput from day one. More output in less time means more money saved and
more revenue made. You get higher efficiency, more productivity, and increased durability in a furnace that is
more rugged and easier to maintain. Plus, every furnace system we provide is designed to your specific
melting application and production requirements. Combine all that with our equipment’s low life cycle cost,
and you’ve just secured yourself a competitive edge for years to come.

Inductotherm Corp. • 10 Indel Avenue, P.O. Box 157 • Rancocas, NJ 08073-0157

1.888.INDUCTO • sales@inductotherm.com • www.inductotherm.com

Important: Appropriate Personal

Protective Equipment (PPE) must
be worn by anyone in proximity
to molten metal.