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ePaper created 2012-06-20, 16:28:00 | version 1.23.6
Technology 32 Issue One 2008 and thus can be tracked and identified. The moulds into which the molten iron is poured are made from sand. They are allow- ed to rest for three hours after casting, until they have cooled to between 400 and 600 de- grees, and then they are separated from the sand again. The fact that the material is given time to cool in this first stage is good for it. Fewer stresses are generated, and as a result the products are sturdier and more durable. To cool the components down again and to separate them from the sand, they pass over a vibrating grid: At the end of this the tem- perature has fallen to about 35 degrees and the coarse sand residues have been removed. The parts are entirely cleaned in the blasting shop, and deburred if required. This process, from the raw material to the finished, unma- chined part, takes about six hours. “We offer quality and we always do our best to be able to deliver on time,” says Wolf- gang Krappe. There are three major competi- tors in the European market: “Fifteen years ago there were considerably more than that.” The foundry has concentrated on its core ar- eas of competence: brake discs, brake drums and flywheels for commercial vehicles. In recent years the installations at Busch have been extended: Of two casting installations, one has been upgraded to the extent that it has replaced the other (older) installation. It has been joined by a new mould-making installation, which is especially designed for brake discs. In operation since 2005, this is now also used to its full capacity, running three shifts, 24 hours a day – only on Sunday does it get a day off. Casting takes place in Photos:Golz The hot iron is as liquid as water but seven times as heavy. The material is given time. »A sample is taken every 15 minutes: Is the raw material as pure as is required?« The path taken by the iron The raw material is smelted at 1,500 degrees. The molten iron is poured into moulds made of sand. It is given three hours to rest – which makes it more durable. The parts cool down further, they are separated and cleaned up.