Reducing scrap, raising quality standards: how AI is transforming the foundry
Rheocasting is an innovative process used in light metal foundries, in which aluminium is processed in a semi-liquid state rather than in a liquid state, as in conventional casting methods. This process improves mechanical properties and reduces porosity compared with conventional high-pressure die casting (HPDC). Nevertheless, process instabilities can still lead to scrap.
AI-supported solutions are crucial for keeping scrap rates low: they reduce emissions, increase output and thus significantly strengthen the sustainability of the business model.
The Salzburg Aluminium Group (SAG), a global leader in rheocasting, faced the challenge of controlling and stabilising the complex process – a task that required an intuitive approach.
To address this, TVARIT’s hybrid AI was implemented, with the aim of minimising scrap rates by improving the first-pass yield rate and reducing costly remelting. To this end, data from rheocasting and HPDC PLC systems, as well as quality databases, were combined to link process and quality aspects.
Based on historical data, the system uncovered previously hidden correlations between process parameters and quality issues. This gave SAG a deeper understanding of the process and enabled it to eliminate the actual causes of scrap. The AI model defined optimal process windows and continuously monitored stability to keep operations within safe limits.
The result: up to 40 per cent less casting-related scrap, greater efficiency and long-term process stability – combined with cost savings and a clear competitive advantage.
“At SAG, we don’t just invent – we turn ideas into industrial reality. To do this, we draw on a deep understanding of processes and use AI to gain insights that make transformation possible ”, explains Fabian Hofstätter, Head of the Rheocasting R&D team at SAG.
Artificial intelligence is the future of efficient foundries – it enables more informed decisions, faster root-cause analysis and reduced emissions.
Contact us today to find out how AI can boost the efficiency of your foundry.