The green sand process is known for super-efficient, high-volume iron casting production. But it can cut the cost of aluminum and many other non-iron castings too. DISA has invested in a new test foundry to prove it. We spoke to Ulla Hartvig Tønnesen, President of DISA, to find out why green sand is ready to disrupt the industry (again).
DISA President Ulla Tønnesen on the power of green sand beyond iron
Ulla, thanks for joining us today. You want more foundries to explore the green sand process for non-iron applications. Tell us why.
Ulla: We want to challenge the industry mindset that certain castings must be made with the same technologies they’ve always been made with. It can be far more efficient to produce suitable aluminum, steel, brass and other non-iron castings in green sand instead of processes like no-bake or gravity die casting that add cost. And you can achieve excellent casting quality and surface finish too.
In a highly competitive global market, moving to green sand for non-iron parts can give a foundry the edge they need. We’re here to make it happen.
What are the main advantages of the green sand process that you want non-iron casting producers to know about?
The obvious one is the cutting-edge automation that shortens cycle times and removes manual labor. Then there’s low-cost tooling, plus fast and easy core handling, and quick pattern changes. Our solutions are known for very quick, high-volume production but ultra-flexible machines like the DISA MATCH and DISAMATIC C3 suit jobbing foundries with short runs and lower outputs perfectly.
We can also add StrikoWestofen’s aluminum melting and dosing technology – plus their expertise – to provide a complete light metal solution. We have lines running in the US, China and elsewhere with this combination.
What sort of overall cost advantage does DISA green sand give?
We typically see a 15% lower cost per casting by switching to green sand, but it can be 20% or more. More automation also lets you redeploy scarce manpower resources into value-creating work instead of standing on a production line. Reusing sand and long tooling life makes green sand more sustainable too.
And where does the new test foundry come in?
Foundries thinking about green sand for non-ferrous castings will have technical questions and we want to convince them that our equipment can support their requirements. So the test foundry will cast their existing parts or new parts, run production trials, and physically prove that we can meet their required specifications. The complete DISA moulding line can validate all parts of the process, from sand composition to pouring and cooling, plus we also offer sand reclaim trials with the SIMPSON Pro-Claim system.
We can test any alloy there, iron or non-iron, and will run our own trials for product development. DISA always pays attention to detail – we want to perfect any customer’s application well before it goes into production.
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“We want to challenge the industry mindset that certain castings must be made with certain technologies.”
Who is best placed to switch to green sand?
It’s a big opportunity for non-iron foundries currently using processes like shell, no bake and die casting. Not every casting is right for green sand but, if it is, you can seriously cut costs and increase profits.
It’s also a way for iron foundries that are already running a DISA foundry to expand their business. Iron volumes are predicted to grow slowly in future while aluminum will keep on growing for sure. They already have the equipment, so can switch much more easily than starting out in die casting or other processes.
Which markets have been most receptive to the idea of using green sand for non-iron castings?
US foundries were among the first to see the opportunity of green sand for non-iron some years ago and we are seeing a lot of interest – and orders – for non-iron applications in China too. Europe is the hardest place to get foundries interested and I think that reluctance to defy tradition is causing big problems for some of them these days.
Many of our major non-ferrous North American customers run the DISA MATCH and one is now ordering its seventh MATCH for brass casting. They will also soon receive our new all-electric auto mould handling (AMH) system.
We already have a customer that makes steel castings coming to the test foundry to trial our process. That is why having this facility is so important. You can simulate a lot but being able to physically check the casting’s surface finish or x-ray it is the best proof of concept you can have.
How else do you support those making the move to green sand?
Besides the test foundry and sales resources, we’ve added more non-ferrous knowledge to our DISA expert process team (Application team) globally.
Our main focus now is to show this often conservative industry just how much they can cut costs by embracing green sand for non-iron castings. Our test foundry helps them take a step out of “business as usual” and see how green sand could work for them.
My message to foundries is: it’s worth exploring green sand together. DISA – and our test foundry – are here to help. Bring us your most challenging non-iron castings and we will work with you to prove they can be produced to specification and at a lower cost in green sand.
Ulla, thank you for your time.