Tilt Casting: Proven Technology taps into New Markets Kurtz Casting Solutions

*Image courtesy of the MOLABO GmbH
and the Helmut Hechinger GmbH & Co. KG
 

A customer relationship between Kurtz Ersa and a foundry often begins with a special customer inquiry. In this specific case, the company “Metal Foundry Brückner” received an inquiry for five different cast parts weighing between three and five kilograms in the summer of 2023. As their new customer held out the prospect of an annual order volume of at least 2,000 pieces each, the previous manufacturing process using sand casting was called into question and the company considered manufacturing with a permanent mold. Permanent mold casting is ideal for producing large quantities economically. As the cast parts are produced in outstanding, reproducible quality, this type of manufacturing is particularly suitable for parts that have to meet highest standards of dimensional accuracy. This was the case for Brückner´s new customer, as the cast parts in question had to meet high quality requirements for drive technology in boat building.

Brückner lands the deal
The strengths of the Brückner metal foundry lie in short delivery times, high quality, and flexibility. The castings produced at Brückner are used in pump technology, electrical engineering, the furniture industry, and railway technology. Continuous investment is defying the current crises and maintaining the production site in Germany. In October 2023, after several preliminary discussions and with its references, the Brückner metal foundry was able to convince the customer and received the order for the first three castings for boat building. Initial simulations followed at Brückner, but these revealed difficulties in the feeding behavior, in particular due to the formation of cavities in unacceptable places.

Cavities are voids that form during the cooling and solidification of molten metal due to the shrinkage of aluminum. The tilt casting process achieves a much higher quality compared to pure gravity casting. Brückner proposed producing three of the five castings using the tilt casting process in order to achieve the highest quality parts. Several meetings were necessary to convince the customer of the benefits of tilt casting, during which the advantages of the process were explained and discussed in detail. The biggest advantage is the controlled filling via the tilting movement of the machine. The mold is filled at a moderate speed, which reduces foaming. Less sprue and feeder weight is required, which has a positive effect on aluminum consumption and results in significant cost reductions. Furthermore, higher unit weights with high complexity and lower wall thicknesses can be better achieved. Better venting in tilt casting leads to fewer air pockets.

Tilt casting passes simulation test
Once the customer was convinced of the tilt casting process, an external toolmaker used simulations to provide insights into the optimum gating technology. The toolmaker also came to the conclusion that tilt casting was the ideal process for the three selected castings. In November 2023, the Brückner metal foundry began looking for a tilt casting machine that would be available at short notice. Until 2023, Brückner always produced for its customers using the gravity casting process. The idea of expanding its own foundry to include tilt casting had been on the company´s mind for some time. Until now, however, there had been a lack of orders with a corresponding demand for cast parts that would have justified an investment. A reliable tilt casting system with a monitored and controlled casting process not only increases the efficiency and quality of the parts produced, but also opens the door to new markets thanks to the expansion of the machinery.

Kurtz Ersa is taken on board
In December 2023, the time had finally come. Brückner contacted Kurtz Ersa, described his needs and shared the exact casting requirements of his customer. An intensive exchange about the requirements for the tilt casting machine began - with the desire to be able to produce very quickly. With a precision landing: Brückner received a commitment from its new customer on 22.12.2023 - the last working day before the Christmas holidays - to manufacture the castings using the tilt casting process. Kurtz therefore also received the machine order from Brückner directly on 22.12.2023. The realization of the project started at full speed in the new year. Numerous meetings between Brückner, their toolmaker and Kurtz were necessary until the optimum casting design was available. At the same time, the machine was produced at Kurtz Ersa´s main plant in Wiebelbach. In mid-June 2024, the time had finally come: the new tilt casting machine was delivered to the Metal Foundry Brückner in Zeulenroda-Triebes. The machine was aligned, anchored to the floor and put into operation. Following the successful casting of the first samples in July, series production can now begin seamlessly.

The Kurtz Casting Solutions team would like to express its appreciation for the excellent cooperation
and trusting relationship during the project phase. We look forward to a long-term business relationship 
with many more projects of this kind.