DISA has established a new test foundry in Denmark to help aluminium, steel, brass, bronze, and iron casting producers adopt the highly efficient green sand moulding process. Designed by DISA's foundry technology experts, the facility will conduct production trials to demonstrate that the green sand method can meet both casting specifications and cost requirements.
DISA aims to make it easier for casting producers to switch from more expensive processes like die casting or no-bake, potentially reducing costs by up to 20 per cent, says DISA President Ulla Hartvig Tønnesen.
"We typically see a 15 per cent lower cost per casting by switching to green sand, but it can be 20 per cent or more. It's a big opportunity for non-iron foundries currently using processes like shell, no bake and die casting," said DISA president Ulla Hartvig Tønnesen.
The test foundry offers comprehensive, end-to-end process development using its full green sand production line. This includes melting, sand mixing, vertical moulding, core shooting, metal chemistry analysis, and MAGMASOFT simulation for optimising gating and feeding design. Foundries can also send sand samples to evaluate Simpson sand reclamation and determine the percentage of sand that can be effectively reused.
Currently focused on steel castings, the test foundry will shift its attention to different alloys every few months, with regular updates shared on DISA's LinkedIn channel. The facility has already demonstrated to a major US foundry that the DISAMATIC D3 vertical moulding line is an ideal solution for brass castings. Ultra-flexible machines such as the DISA MATCH and DISAMATIC are already widely used for short-run aluminium, brass, and bronze casting applications.
"We want to challenge the industry mindset that certain castings must be made with certain technologies. DISA invented high-efficiency, high-quality vertical moulding and perfected it for 60 years. We're seeing more foundries investigate green sand for aluminium, steel, brass and bronze applications, and this facility will give them the confidence to move ahead with production in green sand," added Ulla.
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