Virtual Reality & Environmental Protection: Foundries of the Future

You are a foundry engineer with 30 years’ experience in the foundry industry. What have been the biggest changes during that time?

That’s an interesting question that’s often asked but can’t be answered in a single word. Undoubtedly, it’s the level of automation – and, above all, the use of robots – which has now become indispensable in foundries. New inorganic binder systems for moulds and cores are also essential for reducing emissions.

As an energy-intensive sector, foundries play a significant role in terms of environmentally friendly production processes. A major shift in thinking has taken place here in recent years, and the first foundries are on the way to developing increasingly energy-neutral production processes. Light metal foundries, in particular, play a major role in this regard.

A rather negative aspect is the increasingly apparent shortage of skilled workers. Universities, colleges and technical colleges in particular have a duty to address this.

What role does dry ice blasting technology play in the foundry industry?

With this innovative process, it is essential to emphasise not only the environmentally friendly aspect, but also the results of the blasting process. For example, no other cleaning process can clean a core box as quickly. Furthermore, this type of cleaning is gentle on the moulds, moulds or core boxes.

How do you rate dry ice blasting technology compared to alternative cleaning methods?

The sudden temperature difference causes the layer to be removed (for example, binder residue in core boxes) to cool rapidly and become brittle. This creates cracks in the layer, into which the dry ice particles settle and sublimate into a gaseous state upon impact. As the volume of the carbon dioxide increases significantly in the process, the layer to be removed is dislodged. This means that during the phase transition, the dry ice skips the liquid state. Consequently, no solid or liquid blasting material remains after dry ice blasting. When used correctly, the surface to be cleaned is not damaged, so no abrasion (removal of material) takes place. This is the major advantage of this process and, incidentally, the items to be cleaned do not need to be removed from their mounting.

What services do you offer foundries as an engineer?

First and foremost, it involves temporary on-site support directly at the foundry to resolve issues such as those relating to melting technology and metallurgy, mould and core technology processes, complete production processes and the like. A key focus is on reducing scrap. We offer support in identifying, interpreting and preventing scrap and microstructural defects, and implement the solutions directly on site together with the foundry staff.

Last but not least, we offer training for foundry staff in the fields of metallurgy, mould and core making, process technology and quality assurance.

In addition, our ‘www.giessereilexikon.com’, an encyclopaedia of consolidated specialist knowledge, is available free of charge to any interested reader.   

What major trends do you see on the horizon for the foundry industry, and what changes can we expect?

Here I would just like to highlight a few key points that will occupy us in the coming years: digitalisation – virtual reality – environmental protection and the conservation of raw materials – additive manufacturing – further automation.