DISA has built a new test foundry in Denmark to support producers of aluminium, steel, brass and bronze castings in adopting the highly efficient greensand moulding process.
The test facility will run production trials for new and existing castings to physically prove that the greensand process meets both casting specifications and cost expectations. The test facility will also aid foundries producing iron castings.
DISA president Ulla Hartvig Tønnesen wants to make it easier for casting producers to unlock the potential of greensand for their castings, instead of using more costly methods like diecasting or no-bake – and cut costs by up to twenty per cent.
“We want to challenge the industry mindset that certain castings must be made with certain technologies,” says Tønnesen. “DISA invented high efficiency, high quality vertical moulding and perfected it for sixty years. We’re seeing more foundries investigate greensand for aluminium, steel, brass and bronze applications, and this facility will give them the confidence to move ahead with production in greensand.”
UP TO TWENTY PER CENT COST REDUCTIONS
“We typically see a fifteen per cent lower cost per casting by switching to greensand, but it can be twenty per cent or more,” she said. “It’s a big opportunity for non iron foundries currently using processes like shell, no bake and diecasting.”
The test foundry conducts intensive, end-to-end process development using its complete greensand line. That includes melting, sand mixing, vertical moulding and core shooting, plus metal chemistry analysis and MAGMASOFT simulation for gating and feeding design. Foundries can also submit sand samples to test Simpson sand reclamation and find out what percentage can be reused.
“It’s hard to make a breakthrough on your own,” says DISA’s innovation manager, Per Larsen. “Partner with us if you have a non iron casting you would like to produce in greensand – we’re here to help.”
GREENSAND GIVES YOU AN EDGE
Currently working with steel castings, the test foundry will focus on a different alloy every few months, with regular updates via the DISA LinkedIn channel. The facility has already proved to one major US foundry that a DISAMATIC D3 vertical moulding line is perfect for its brass castings.
Ultra flexible machines like the DISA MATCH and DISAMATIC are already widely used in short run aluminium, brass and bronze applications.
Tønnesen enthused: “Not every casting is right for greensand but, if it is, you can seriously cut costs and increase profits.
“It’s also a way for iron foundries that are already running a DISA foundry to expand their business. Iron volumes are predicted to grow slowly in future while aluminium will keep on growing for sure. They already have the equipment, so can switch much more easily than starting out in diecasting or other processes.
“In a highly competitive global market, moving to greensand for non iron parts gives foundries the edge they need. We – and the DISA test foundry – are here to make it happen.”
DISA, a Norican Group technology, develops and manufactures a complete range of metal casting production solutions for the ferrous and non-ferrous foundry industries. Headquartered in Taastrup, Denmark, with a North American facility based in LaGrange Georgia, DISA is a world leading supplier of complete foundry solutions and services, as well as state-of-the-art greensand moulding equipment.
DISA also offers its class-leading Monitizer digital solutions that support the whole digital journey from data collection to AI-driven casting quality optimisation. Monitizer works in all types of foundries and processes, and with any vendor equipment, to deliver serious process improvements.
www.disagroup.com