SinterCast AB

Kungsgatan 2, 641 30 Katrineholm
Sweden
Telephone +46 150 79440
Fax +46 150 79444
steve.dawson@sintercast.com

Location

Hall map

GIFA 2015 hall map (Hall 10): stand F60

Fairground map

GIFA 2015 fairground map: Hall 10

Our range of products

Product categories

  • 18  Control systems
  • 18.01  Process control, models, simulation

Process control, models, simulation

  • 18  Control systems
  • 18.02  Control equipment, automation technology

Control equipment, automation technology

  • 19  Measurement and test technology
  • 19.01  Measuring instruments
  • 19.01.01  Temperature measuring instruments

Temperature measuring instruments

  • 19  Measurement and test technology
  • 19.01  Measuring instruments
  • 19.01.02  Thermal analysis equipment

Thermal analysis equipment

Our products

Product category: Process control, models, simulation

SinterCast Process

The SinterCast process begins with an accurate thermal analysis of the base treated iron, conducted in the patented SinterCast Sampling Cup. Based on the result of this measurement, corrective additions of magnesium and inoculant are automatically added to each ladle, in wire form, to optimise the composition of the iron prior to casting. During series production, the average corrective addition of magnesium is approximately 20 grams per tonne. The two-step measure-and-correct control strategy eliminates process variation and ensures cost-effective CGI series production, with consistently low nodularity. The SinterCast process provides discrete results for Carbon Equivalent, Magnesium and Inoculation for each ladle. These results, together with wirefeeding amounts and other process data, are displayed to the operators and available for automatic downloaded to the foundry quality system to satisfy QS9000 traceability requirements.

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Product category: Process control, models, simulation

The Advantages of CGI

Compacted Graphite Iron is an engineered form of cast iron. It is at least 75% stronger and 45% stiffer than the standard grey cast iron and aluminium alloys. More importantly, CGI provides double the fatigue strength of grey iron and up to five times the fatigue strength of aluminium at elevated temperatures. The improved properties of CGI enable design engineers to reduce the size and weight of components, and/or to increase operating loads. CGI is ideally suited to components that have simultaneous mechanical and thermal loading, such as cylinder blocks and heads, exhaust manifolds, turbocharger housings and clutch components.

Compacted Graphite Iron allows engine designers to improve performance, fuel economy and durability while reducing engine size, weight, noise and emissions. CGI enables automotive engines to be 10-20% lighter than conventional cast iron engines and 10-20% shorter than aluminium engines. The reduced length means that all of the components that span the length of the engine are also shorter, and therefore lighter. The net result is that fully assembled CGI engines can effectively be the same weight as, or even lighter than, aluminium engines. CGI also allows for 10-20% increased specific performance (kW/litre), 75-100% improved durability, and 5-10% reduced operating noise. The strength and stiffness of CGI maintains the dimensional accuracy of the cylinder bore and allows engines to satisfy emissions legislation throughout the life of the vehicle.

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Product category: Control equipment, automation technology

System 3000

The System 3000 provides a flexible, robust and accurate platform for independent CGI series production and product development. The System 3000 is comprised of a series of individual hardware modules that can be configured to suit the layout, process flow and production volume of any foundry, for CGI production from ladles or from pressurised pouring furnaces. Beyond the core CGI process control, the System 3000 is also capable of collecting series production data from the foundry process, including chemistry analyses, temperatures, ladle weight and moulding line information, to compile the data into a single information system for improved traceability. All process results are available to the foundry engineers to enable independent process control and product traceability.

The System 3000 Plus is an extension of SinterCast’s System 3000 that includes automated base treatment of magnesium and inoculant. The automatic base treatment by cored wire is based on automated input of ladle weight, temperature, and historical SinterCast analysis results from previous ladles. Automated base treatment prior to the measure-and-correct process control strategy enables foundries to reduce the variation of the base treatment process, thereby increasing the overall robustness of the CGI casting process.

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Product category: Temperature measuring instruments

Mini-System 3000

The Mini-System 3000 is based on a simplified hardware version of the fully automated System 3000. The Mini-System 3000 has been specifically developed to provide a cost-effective platform to allow foundries to install CGI production capability in support of initial product development activities or niche volume CGI production. The Mini-System 3000 uses the same sampling technology and software as the fully automated System 3000 and all product calibrations developed with the Mini-System 3000 can be directly transferred to the fully automated System 3000 for series production.

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Product category: Thermal analysis equipment

SinterCast Thermal Analysis

SinterCast’s technology, utilising the patented Sampling Cup, provides consistent CGI series production control within a narrow range at the lower end of the ISO 16112 0-20% nodularity specification for CGI, where casting defects are minimised and thermal conductivity and machinability are optimised. The SinterCast Sampling Cup is the most accurate thermal analysis device available in the market and is the subject of five patents related to its design and an additional eight patents related to solidification and thermal analysis.

The prominent features of the Sampling Cup include:

  • Steel Fabrication – the steel fabrication ensures accurate dimensional tolerance for consistent cooling conditions.
  • Representative Iron – immersions sampling prevents metal oxidation during filling and ensures that the iron in the Sampling Cup is the same as the iron in the ladle. Immersion sampling also pre-heats the Sampling Cup to prevent chill solidification.
  • Constant Volume – the overflow design of the Sampling Cup allows easy sampling and ensures constant iron volume for reproducible cooling conditions.
  • Mg Fade Simulation – magnesium fading is simulated at the bottom of the Sampling Cup to ensure control of the graphite microstructure from the start until the end of casting.

The SinterCast cooling curves are obtained from two re-usable thermocouples located in a protective steel tube within the Sampling Cup. Each Thermocouple Pair is calibrated, temperature tested, and thermally cycled prior to delivery. The Thermocouple Pair can be used for up to 250 samples with no loss of accuracy prior to preventive replacement. At the end of service, the Thermocouple Pair can be conveniently replaced in less than one minute. Barcode labelling of each Thermocouple Pair allows the calibration factor to be compensated for in each analysis and provides traceability for QS9000 requirements. SinterCast has successfully used re-useable thermocouples since 1999, providing class leading accuracy, traceability, and performance.

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About us

Company details

SinterCast is the world’s leading supplier of process control technology for the reliable high volume production of Compacted Graphite Iron (CGI). With 40 installations in 12 countries, the SinterCast technology is primarily used for the production of petrol and diesel engine cylinder blocks and exhaust components for passenger vehicles; medium-duty and heavy-duty cylinder blocks and heads for commercial vehicles; and, industrial power engine components for marine, rail, off-road and stationary engine applications. SinterCast’s series production components range from 2 kg to 9 tonnes, all using the same proven process control technology. The SinterCast process control technology is used for the production of more than two million CGI components per year. SinterCast has local offices in Sweden, UK, USA, China, and Korea.

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Company data

Foundation

1983