Moulding Materials

The dimensional accuracy of castings, particularly for filigree geometries, is essentially influenced by the distortion of the inserted sand cores during the pouring. This aspect of the casting process, which has hitherto received little consideration, has gained in importance due to the increase in inorganic binder systems and the concomitant process modification. The objective of the research is to understand and, by using simulations, to predict the distortion of the sand core and the pertinent, distortion-relevant influencing parameters for the component’s dimensional accuracy as well as to minimise both future unavoidable distortions by taking these into consideration in designing the core boxes.

Core shooting

The spectrum of core shooting aggregates ranges from a few cubic centimetres of core volumes up to 12 litres. Here, almost all core binder systems can be employed. The centrepiece of the equipment installation is a 12 litre, Röper FCJ12C-K core shooting machine which, coupled with universal gassing equipment and operated semi-automatically, meets industrial requirements. Owing to its flexible design, this machine is suitable for carrying out both basic research as well as industrial projects.

The service portfolio ranges from support during the core-box design and prototyping to small batch manufacturing. Laboratory samples as well as cores are manufactured for die and sand casting real components.  Modelling of core gassing is also investigated in the basic research projects.

Rapid Prototyping

Rapid prototyping has increasingly established itself within the foundry industry for manufacturing moulds and patterns for prototypes and small batches. Besides lost-patterns for precision (investment) casting, sand moulds can also be manufactured using our own rapid prototyping equipment.