Process control solutions for compacted graphite iron
SinterCast provides process control solutions and know-how for the reliable high-volume production of compacted graphite iron (CGI), which is a high-strength cast iron that improves the efficiency of components used in cars, heavy vehicles and industrial power components.
Process control solutions for automotive suppliers
SinterCast’s technology measures and controls the molten iron before it is cast in moulds to ensure cost-effective series production of CGI. The technology reduces foundry discards and therefore lessens the environmental impact of the foundry process. SinterCast has been a global leader in product development and serial production of CGI since 1992. These efforts have established SinterCast as a credible supplier to the global foundry and automotive industries. SinterCast’s goal is to continue promoting new CGI applications based on current series production to increase market opportunities. In parallel, SinterCast will develop new products and services to broaden and deepen existing customer relationships. SinterCast will also explore new product development opportunities in addition to its core CGI business to increase shareholder value in the long term.
Compacted graphite iron
Compacted graphite iron (CGI) is a type of iron that gives at least 75 % higher tensile strength, 45 % higher stiffness and an approximate doubling of fatigue resistance compared to conventional cast iron and aluminium. The properties of CGI allow engineers to improve performance, fuel economy and durability while reducing engine weight, noise and exhaust emissions. SinterCast’s process is also used in the manufacture of castings for a variety of CGI components, including engine blocks and cylinder heads, bedplates, turbo housings, exhaust manifolds, coupling components, piston rings, cylinder linings and large engine components for industrial power applications.
SinterCast’s technology is used in 12 countries in 21 foundries for the production of more than 50 CGI components in sizes ranging from 2 kg to 17 tonnes, all produced using the same process control technology. A further 15 foundries have installed process control systems for product development and R&D activities. End users of SinterCast CGI components include Aston Martin, Audi, Cameron Compression, Caterpillar, Chrysler, DAF Trucks, Ford, Ford-Otosan, General Electric Transportation Systems, General Motors, Hyundai, Jaguar, Jeep, Kia, Lancia, Land Rover, MAN, Navistar, Porsche, PSA Peugeot-Citroën, Renault, Rolls-Royce Power Engineering, Scania, Toyota, VM Motori, Volkswagen, Volvo and Waukesha Engine.
SinterCast sells or leases the hardware for its System 3000, leases the system software, sells sampling consumables and charges a production fee for every tonne of castings produced using the SinterCast technology. There are also revenues from spare parts, customer service, customer demonstrations and sales of test pieces. The total actual production costs (sampling consumables plus production charges) depend on ladle size and replacement for casting for each foundry and each product. A typical engine block production line provides revenue of around EUR 40-50 per tonne of castings, representing EUR 2.00-2.50 for each engine equivalent of 50 kg. SinterCast’s business model is highly scalable, providing higher profitability as the installed base increases and more programmes come into series production.