Advanced Core Solutions at GIFA 2019

Innovation Made in Germany

The ACS Team presented the innovation for electrical sand core hardening at the Gifa in in June 2019. The stand was located at the section “Innovation Made in Germany” and attracted interested from all continents and more than 25 countries. 

 

IQ Innovation Award 2019

Award for Sand core hardening innovation in automotive cluster.

The ACS Team received an award for the 2nd place out of more than 150 innovations submitted. The Award ceremony took place in Leipzig, Germany in June 2019.
Contact us to learn more about our innovation.

 

Advanced Core Solutions - Green

eco-friendly core making

for all existing inorganic binders

Advanced Core Solutions - Cost Effective

Cost effective rework of

existing core making machines

Advanced Core Solutions - Faster

Faster core making and better hardening

Advanced Core Solutions

Future of core making

Overview Core Making Processes

Organic Processes 

Organic Process
Cold Box

The molding material and the two-component binder are cured at ambient temperatures by means of amine gassing. The after-treatment of the amingase has a decisive influence on the efficiency of the process.

Organic Process
Hot Box

Curing the molding material / quartz sand by heated core boxes while feeding the temperature at about 350 to 400 degrees Celsius and the appropriate removal of the core gases by means of core marks or slot nozzles.

Organic Process
Croning

Croning is a masking process. The hardening of the resin-sand mixture in the molding material takes place by means of heat supply.

 

Inorganic Processes 

Inorganic binder

Inorganic binder systems are usually based on the use of 2 components. The binder and a promoter together enable the sand core to harden. The desired sand core properties can be positively influenced by means of additives based on the required properties.

 

Inorganic process
Cordis by Hüttenes Albertus

The “Cordis” binder from Hüttenes-Albertus is a two-component binder with a highly reduced emission output. The sensitivity to humidity and other properties can be positively influenced by the addition of additives.

 

Inorganic process
Sodium Silicate

The binder is cured in the molding material by gassing with CO2 and can be improved with additives such as esters or other chemicals.

 

Overview Core Making Processes

Organic Processes 

Organic Process
Cold Box

The molding material and the two-component binder are cured at ambient temperatures by means of amine gassing. The after-treatment of the amingase has a decisive influence on the efficiency of the process.

Organic Process
Hot Box

Curing the molding material / quartz sand by heated core boxes while feeding the temperature at about 350 to 400 degrees Celsius and the appropriate removal of the core gases by means of core marks or slot nozzles.

Organic Process
Croning

Croning is a masking process. The hardening of the resin-sand mixture in the molding material takes place by means of heat supply.

Inorganic Processes

Inorganic binder

Inorganic binder system are usually based on the use of 2 components. The binder and a promoter together enable the sand core to harden. The desired sand core properties can be positively influenced by means of additives..

Inorganic process
Cordis by Hüttenes Albertus

The “Cordis” binder from Hüttenes-Albertus is a two-component binder with a highly reduced emission output. The sensitivity to humidity and other properties can be positively influenced by the addition of additives.

Inorganic process
Sodium Silicate

The binder is cured in the molding material by gassing with CO2 and can be improved with additives such as esters or other chemicals..

New patented process

Our newly patented process allows a reduction of cycle times of up to 33% with unchanged use of existing inorganic binder mixtures. This is achieved by a complete different approach of core shooting systems and the appropriately adapted core box materials. All further advantages with the use of inorganic binders remain.

 

Overview of advantages versus current
core making processes

 

  • Shorter cycle times up to 33%
  • Uniform curing of every part of the sand cores
  • Higher flexural strength
  • Lower energy consumption
  • Use of existing binder mixtures
  • No post curing required
  • Larger sand core thickness can be achieved (>40mm)
  • Lower wear on the core boxes
  • Higher equipment availability due to less downtime
  • Cost-effective conversion of existing plants

Advanced-Core-Solutions (ACS) in the News

TECHNOLOGIE & TRENDS (Translated from German)

Development of a new process for the electrical hardening of inorganic sand cores and forms

Inorganics continues to gain importance for sand core production. The development of a newly technology for curing inorganic sand cores by means of electricity strives for the faster and cost-effective production of inorganic sand cores. The other advantages such as low energy consumption with homogeneous hardening are very promising.

Die GIESSEREI

First published in GIESSEREI 01/2019, More foundry topics can be found at www.giesserei.eu

Focus Casting – Innovations and Development Trends (Translated from German)

Faster and more efficient production of lost cores for mass production

However, the hardening of the inorganically bound cores takes a new approach and seeks to be both more efficient and more environmentally friendly than previous methods. […] Cycle time savings of up to 30 percent can be expected […]

Mitteldeutsche Mitteilungen

Publication 01/2019, VDI - Verein Deutsche Ingenieure

Development of a newly patented process to speed up the hardening of inorganic sand cores

The new technology promises a high potential to improve the efficiency of sand core manufacturing while reducing the energy consumption.

Sand cores are the backbone of modern foundry products and enable the most complex shapes. A newly patented process improve the inorganic sand core hardening by up to 33%. […] All in all a significant cost and time reduction of up to 33% is foreseen versus conventional core hardening processes. This is mainly driven by 3 aspects: Energy consumption, cycle time and maintenance cost. All benefits are currently explored during lab trials and will be confirmed in identified projects in the near future.

foundry-planet.com

Publication 01/2019, www.foundry-planet.com

Energy savings through ACS process for current hardening of sand cores

ACS – Advanced-Core-Solutions has the jury of the cluster Automotive 
with their presentation convinced and is now one of the two finalists in the Automotive cluster

With the IQ Innovation Award Central Germany we promote innovative, marketable products, processes and services in five sector-specific clusters. In addition, an industry-independent jury will select one of the ten finalists from the clusters for the overall winner of the competition.

IQ - Innovation Award

Finalist Cluster Automotive 05/2019, www.iq-mitteldeutschland.de

Award for the ACS – Advanced Core Solutions-Team by the IQ Innovation Award 2019

The team behind ACS-Advanced-Core-Solutions won the 2nd price in the automotive cluster for their innovation of electric sand core hardening at this year IQ Innovation Award.

The award ceremony took place in Leipzig and in parallel to this year’s GIFA. The award ceremony was located at the Paulus Church in Leipzig and local industry, politics and press representatives joined the event. The ACS Team also received during the GIFA immense interest from various continents which concluded a successful week.

Giessereilexikon

News 07/2019, www.giessereilexikon.com/

Sand core making in foundries

 

The global foundry industry is constantly changing. Technology improvement in the foundry industry enable better products for consumers and companies.

 The constantly growing economic and sustainability requirements ensure a constant focus on the improvement of existing foundry processes. This focus on foundry industry also requires improvement in sand core making for the various casting processes.

Experts

Foundries are nowadays successful due to their expertise and especially due to strong networking across partners in the foundry industry. Suppliers and customers become partners and contribute to effective production of complex moulding products.

The right choice of machine manufacturers, binder suppliers, sand producers and core box builders is the basis for further future-proof developments of existing casting solutions.

Please contact us for further information or a demonstration of the new process

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