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Insights from DISA On the Way Towards Zero-Defect Production

Editor: Isabell Page

Over the next six years, aluminum consumption is expected to rise to 120 million tonnes. Talking to Michael Colditz, Global Product Manager Horizontal and Non-Iron Solutions at DISA, we got exciting insights into the developments taking place to help support new and existing aluminum foundry customers.

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Since green sand iron casting has proven its worth, green sand is becoming increasingly interesting for aluminum components.
Since green sand iron casting has proven its worth, green sand is becoming increasingly interesting for aluminum components.
(Source: Norican Group)

DISA has been offering greensand solutions for aluminum for many years, especially in relation to automotive where prototypes of aluminum components have traditionally been produced by sand casting.

However, with demand for aluminum components in vehicles now increasing - in particular due to the parallel development of alternative drive systems – manufacturers, and subsequently OEMs, are looking to reduce costs by utilizing new technologies from their suppliers. DISA has responded by looking at ways to expand its offering.

In particular, the Norican technology has developed a new process that allows increased filling by casting the sand mold from below. The result is a cycle time that is 10 to 15 seconds faster – a significant development in cost-efficient production given that, according to a nationwide survey by Cantar Emnid, alternative drives are attractive for Germans if it wasn’t for the purchase prices.

New Possibilities of Traceability

To ensure the best possible use of new solutions, the Norican subsidiary is in direct contact with OEMs and foundries. This is also how the new Trace and Guidance (TAG) concept was created.

Particularly responding to the automotive industry's demand for traceability of cast components, TAG’s primary objective is to help customers avoid rejects. Using the TAG methodology, each casting is assigned a unique ID number, creating the connection between rejected castings and their individual process parameters. We also spoke with Per Larsen, Portfolio and Innovation Manager at DISA, about the topic, who highlighted that TAG traceability enables an enormous cost reduction and raises quality control to an unprecedented level.

Industry 4.0

The situation is similar with Industry 4.0 applications. These solutions are also expected to be delivered proactively by suppliers to help foundry customers meet changing demands.

The reality is that many foundries already collect vast amounts of data, but often do not use it for further analyses or predictions, which in turn can help make processes more efficient and cost effective. In relation to this point, DISA is once again in demand to provide direction and, above all, meaning to the collection of data.

In addition, the company is particularly engaged in the development of resource-conserving processes, for example to counteract the emerging shortage of quartz sand. Topics such as additive manufacturing are also playing an increasingly important role here.

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