Mould and core coatings can significantly influence a foundry’s manufacturing costs. The displays will highlight specific examples of Foseco’s innovative approach to reduce casting manufacturing costs through product development and by enhanced coating application technologies. Highlights include the launches of an innovative new coating range for automotive foundries to fulfil most stringent demands on inner cleanliness and a state-of-the-art coating application control system to improve the consistency of coating at the point of application.
Coatings can have a direct influence on automotive engine performance and contribute directly to the achievement of the environmental aspects of Euro 6 and Euro 7 regulations. By optimising the inner cleanliness of critical cavities in castings such as cylinder heads and engine blocks, longer service intervals and reduced cooling and lubrication liquid exchange can be achieved. Foseco will showcase a new range of so called “inner cleanliness” coatings SEMCO IC than enable automotive foundries to move from suppliers to engine design partners.
The next generation of engine blocks have increased demands on strength and integrity at the same time as the desire to reduce the overall weight of the components to improve fuel efficiency. For larger engine blocks for automotive and commercial vehicle applications, grey iron is being superseded as the material of choice by newer materials such as compacted graphite iron (CGI). The formation of a flake graphite skin can lead to reduced mechanical properties, an increased allowance for machining or an increase in the casting wall-thickness to accommodate for this disruption, incurring extra costs or limiting design optimisation.
ACTICOTE CG coatings have been especially designed to reduce unwanted interactions at the metal / core interface and minimise the flake graphite skin formation in CGI castings.