These were our exhibits
Welcome to our exhibits section, where we will be showcasing all the exciting innovations and technologies we were exhibiting at GIFA 2023. Our exhibits have been carefully selected to highlight the latest advances in foundry technology and metallurgy, and we can't wait to share them with you.
In this section you will have the opportunity to browse each exhibit in detail, with detailed descriptions, case studies, images and videos to give you a full understanding of each display. Our team has worked tirelessly to ensure that each exhibit is presented in a way that is both informative and visually appealing.
Click on your area of interest below.
> Non Ferrous FoundryFDU MTS SMARTT
SMARTT Degassing is an innovative process control for rotary degassing of aluminium alloys. The SMARTT software accurately simulates rotary degassing and predicts the best treatment practice based on ambient conditions, melt temperature, rotor design and alloy composition.
Degassing Rotors
Foseco offers eight different combinations of rotor design and material to enable foundries to choose the most appropriate degassing rotor to suit their requirements.
Advanced Drossing Fluxes
Not every drossing flux is the same. Learn how careful selection and application of drossing fluxes can significantly reduce the amount of valuable aluminium content trapped in the dross layer.
Aluminium Motor Housing for VW ID.3 / ID.4
Case study of an aluminium motor housing for the electric vehicle VW ID. 3 / ID.4, showing how our melt treatment solutions with SMARTT process control and grain refinement with NUCLEANT 1582 led to a reduction in casting scrap.
WASCO water soluble binders for high pressure die casting
Case study demonstrating the ability to manufacture castings with more complex internal designs using the high pressure die casting process. An aluminium instrument housing for industrial applications produced by Limatherm in Poland was made water soluble high strength sand cores that can withstand high casting pressures whilst being easy to remove from the finished part.
ZF aluminium gear box housing
Case study of AlSi9Cu3, ZF Group gearbox housing (70 kg), showing how FDU rotor degassing and flux application in high pressure die casting are used to deliver the highest casting quality properties demanded by the automotive sector.
Optimised metal treatment practices for high pressure die casting at Tuğçelik, Turkey save money and improve quality
Case study of aluminium sun roof components for BMW produced via the high pressure die casting process showing how the combination of advanced granular fluxes and superior degassing rotor designs minimise aluminium content in the dross, reduce oxide formation and improve the working environment
Yield optimisation for an aluminium gearbox from Morini
Case study of an aluminium gearbox housing produced for ZF by Morini Foundry in Italy showing how the applications of FEEDEX NF1 sleeves reduced casting weight and feed volume thereby reducing energy consumption, lowering fettling costs, minimising remelting and improving productivity.
Yield optimisation for a brass water culvert from Pleiger
Case study of a brass water culvert manufactured by Pleiger in Witten, Germany showing how the application of FEEDEX NF1 sleeves led to the reduction of melting and fettling costs.
Long life die coatings for low pressure wheels at BBS
Case study of an aluminium wheel for the automotive industry from manufactured BBS Schiltach in Germany showing how the application of DYCOTE SAFEGUARD low pressure die coatings provide extended service life with increased productivity and reduced downtime.
Extending aluminium melting crucible life at Mahle Poland
Case study of a clay graphite crucible for melting aluminium from Mahle in Poland showing how the application of this improved technology delivered 70 % more lifetime.
Energy saving and long life crucibles
A selection of case studies highlighting the latest advances in ENERTEK energy saving and DURATEK longer life crucible products.
Enhancing mechanical properties of steel castings with ROTOCLENE rotary cleaning
2 carbon steel case studies from UNEX in the Czech Republic showing how the deployment of the ROTOCLENE rotary cleaning process and HOLLOTEX Shroud technology delivered enhanced casting properties and longer casting life whilst drastically reducing rework.Latest advances in flow control for iron and steel foundries
Foseco’s best-in-class range of stoppers and nozzles maximise productivity and optimise quality in the melt shop, whilst KALTEK insulating ladle lining systems maintain a cleaner melt and save energy.
VAPEX Fosflow adjustable nozzle case studies from Cascara and FAS
Case studies from Cascara in Spain and FAS in Italy (Italy) showing how the VAPEX FOSFLOW system enable foundries to rapidly change nozzle diameter, even in a full ladle without the need to remove and replace the nozzle and stopper.
Metal stream shrouding at UNEX in Czech minimises rework operations
2 carbon steel case studies from UNEX in the Czech Republic showing how the deployment of the ROTOCLENE rotary cleaning process and HOLLOTEX Shroud technology delivered enhanced casting properties and longer casting life whilst drastically reducing rework.
Sensors and probes for iron foundries
Sensors and probes for iron foundries to make your industrial processes safer, more efficient, more reliable and more sustainable
SEMCO coatings range
A range of case studies, showing how the latest developments in water based coatings enable foundries to reduce harmful emissions, improve the working environment and optimise the drying process saving energy and avoiding the potential for surface defects.Optimising internal cleanliness of blocks and heads at Volvo
Case study of a large Industrial/Truck engine block and head manufactured by Volvo in Skovde Sweden demonstrating how improved internal cleanliness enables longer service intervals, better engine performance and reduced emissions
Customisable, modular coating density control systems
Foseco’s modular intelligent coating unit (ICU) is the latest addition to the ICU range which enables a foundry to customise the installation and build up coating control capabilities step by step.
Hand held coating density measurement systems
Hand held coating density measurement devices enable the busy operator to quickly assess coating properties anywhere in the foundry, ensuring consistent coating application and thereby consistent casting results.
Delivering improved metallurgical properties in thin sections iron castings with ACTICOTE TS coatings
Case study of a grey iron test casting showing how the application of ACTICOTE TS delivers improved metallurgical properties for thin walled sections for critical applications such high performance internal combustion engines.
Improving surface finish in iron castings using 3D printed cores at Mezger, Switzerland
Case study of a 3D printed large and heavy core for a ductile iron gear housing manufactured by Mezger AG in Switzerland showing how the application of the new Foseco TENO PRINT 5781 A coating led to improve casting surface and the reduction of rework and scrap.
Replacing phenol with sustainable biopolymers in ECOLOTEC gas cured binders at Fondium, Mettmann
Case study of a ductile iron automotive differential housing produced by FONDIUM Mettmann GmbH for Daimler showing how the application of a biopolymer-based ECOLOTEC binder (LPF resin) reduces the carbon footprint and improves the odour in the core-shop.
Extending tool life and reducing fire hazard at Condals, Spain
Case study from a grey and ductile iron green sand foundry in Spain demonstrating the environmental benefits of PARTISAL ECO low fume parting agents. The excellent release and lubricating properties of PARTISAL ECO extend tool life and the elevated ignition temperature of the parting agent significantly reduces the risk of expensive fires on the moulding line.
Optimising steel casting surface finish without using zircon at Pyrsa in Spain
Case study of heavy carbon steel castings produced by Pyrsa Foundry in Spain showing how TENO Tec ZA zircon free coatings match the performance of zircon based products and avoid the issues of inherent radioactivity and price volatility associated with traditional coatings.
How to achieve filtration efficiency and good flow rates with STELEX Optiflow 3D printed filters in iron castings
Case study of a ductile iron cross head casting for a die casting machine, showing how the application of STELEX OptiFlow 3D printed filters combined with an SCK Direct Pour led to improved yield, less fettling and reduced costs.Lightweight runners and printed filters improve yield and surface finish in steel castings at Eickhoff, Germany
Case study of a steel planet carrier for a small gear box, showing how the application of HOLLOTEX EG Runner ST and STELEX Optiflow 3D printed filters led to improved surface finish, faster handling and less wear in sand operating machines.
HOLLOTEX EG lightweight runners for steel improve productivity and reduce waste at Schmees Langenfeld
Case study of a steel housing for the food industry, showing the application of lightweight HOLLOTEX EG Runner ST running and gating components together with STELEX ZR filters led to improved and faster handling and less waste in the foundry.
Reducing fluoride levels in waste sand without compromising on feed performance at GF Leipzig
Case study of a ductile iron casting for an agricultural machine, showing how the application of FEEDEX FEF VAK sleeves led to sound castings and reduced disposal costs through the avoidance of fluoride contamination of the sand system.
Tailored feeding solution leads to reduced rework and improved yield at Ironworks, Italy
Case study showing how a customised FEEDEX VAK spot feeding solution on a ductile iron carrier casting enabled yield improvement and fettling savings to be achieved despite space restrictions on the pattern plate.
The application of reduced height, high modulus spot feeders at Ironworks, Italy
Case study showing how FEEDEX VAK sleeves overcame height restrictions due to the elevated position of the spot feeders on the cope. The customised design ensured that the sleeves achieved a sufficient modulus to enable spot feeding whilst delivering shrinkage free castings.
Feeding heavy isolated sections in ductile iron castings on a vertical moulding line at Cheng Pao Foundry
Case study showing how the application of FEEDEX K feeders enable Cheng Pao Foundry to feed isolated heavy sections in the centre of a ductile iron clutch plate produced on a vertical moulding line. Metal padding was eliminated, improving yield and reducing fettling costs and shrinkage related defects were significantly reduced.
Conversion of ductile iron console castings from horizontal to vertical moulding lines through the use of spot feeders at Döktas, Turkey
Case study showing how manufacturing costs were reduced through the successful transfer of a ductile iron console casting from a horizontal moulding line to a vertically parted moulding line. Further savings in fettling costs were achieved through minimising the feeder contact area.
Reducing fluoride levels in waste sand without compromising on feed performance at Zanardi, Italy
Case study showing how the application of KALMINEX 2000 FF feeder sleeves on an austempered ductile iron socket casting significantly reduced water leachable fluoride content in the sand system, thereby minimising waste sand disposal costs.