EXPERIENCE

COMPETENCEPASSION

OUR RAW MATERIAL

2,100,000,000 YEARS One of the oldest blocks of stone that contain iron ore bands is 2.1 billion years old. This block has a volume of 6 cubic meters.It was found in North America. Now it is owned by the National Museum of Mineralogy and Geology, Dresden. Ore has been mined by humans for more than 5,000 years. 2,100 years ago, the Romans already had large iron smelting plants, and nowadays approx. 720 million tons of crude steel are produced very year. The company Foundry Service GmbH contributes to the numerous transport processes involving molten materials as well as to heating and holding.

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OURMISSION

FACTORY Foundry Service GmbH specializes in heating and holding as well as in constructing transport installations for molten materials. Besides our long-standing experience and our multi-faceted competence, we are driven by a profound passion for our highly specialized trade. Foundry Service has become one of the market leaders in this industry because of constant innovations andproduct developments which have led to numerous patents. Welcome to Foundry Service

Stefan Brands, Managing Director Iraklis Papadopoulos, Managing Director

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We live the Foundry philosophy in Hemer, the Sauerland town with its Sea of Rocks, right below the Jüberg Tower, at our 130,000 square feet of production space. And we will continue and increase our success by coming up with new developments again and again and serving our customers 365 days a year!

HIGH ENDSOLUTIONS

INDUSTRY 4.0SMART TECHNOLOGYGREEN ECONOMYHIGH PERFORMANCE MATERIALS

Adapting traditional procedures to future demands, managing resources economically, using energy effi ciently. Guiding principles that govern our present and future work, in order to ensure your company’s competitiveness. We use materials such as ultra-lightweight fi ber composites in the liquid metal sector, trans-ponder technology for quality assurance as well as an uninterrupted value chain and high performance materials for a low-loss energy consumption to connect you to the world of tomorrow.

Our patents in the areas of metal production, transport and pouring will ensure you optimum technology for each repair and each new production. High end solutions made by Foundry Service are high tech products that make your company fi t for the future.

It is our objective to recognize your individuality in your local processes and your situation and to keep developing it with you. Our long-term strategy is to approach things differently, not thinking in standard ways. Being available to render our services at any time and any place – those are the vaules all staff members of Foundry Service live by.

Benefi t from our innovative power and the passion to understand you.

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INDUCTION TECHNOLOGYAn alternating current fl ows through a copper conductor, which will induce electricity in metal (conducting) materials. This physical process is used in induction plants to heat or melt metals. This interplay of plant technology is highly complex and connected with great risks, due to the mediums of electricity and water. Maintenance, repair and service are the core competencies of Foundry Service GmbH.

Our strength lies in the ability to obtain optimum quality and service life for your plant. This includes a meticulous care of details, an understanding of the complexity of your plant and the passion to solve your problems and meet your demands. Our patents, together with our know-how, will provide you with a maximum service life for your induction coil, your furnace charge, inductor, or your forge heating unit. We repair, modify and upgrade all components of your plant, no matter where it was manufactured. Our service also includes a storage of your components free of charge. This will ensure that you have an optimum reserve of spare parts at your disposal in case of damage or revisions.

SERVICE

TEST PROCEDURES

POST-FIRE RECONSTRUCTION

DISASSEMBLY AND ASSEMBLY OF USED EQUIPMENT

HIGH-CAPACITY TEST LAB

ACCESSORIES

CONTROL SYSTEMS AND PERIPHERAL PLANTS

CAPACITORS

HYDRAULIC EQUIPMENT

WATER POWER CABLES

TRANSFORMERS AND CHOKES

YOKES

PRODUCTS

INDUCTIVE FORGE HEATING TECHNOLOGY

LINE AND MEDIUM FREQUENCY CRUCIBLE FURNACES

CHANNEL TYPE FURNACES

UPGRADE OF CRUCIBLE AND CHANNEL TYPE FURNACES

SPS CONTROL TECHNOLOGY FOR INDUCTION FURNACES

CONVERTER TECHNOLOGY

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RECEIPT

Arrival of the induction coil at our Hemer plant Recording of damages and writing the workshop order Assessment of trouble spots Disassembly of individual components

PYROLYSIS

In the pyrolysis furnace the copper is annealed stress-free and the old insulation is burned off under exclusion of oxygen

Removal and disposal of the old insulation in compliance with legal regulations

BLASTING

Abrasive blasting of the coil with reduced abrasive effect

Completion of the following tests: 1. Dimensional inspection 2. Water fl ow 3. Hot compression test 4. Helium test

OVERHAULING

INSULATION

Insulation of the induction coil according to manufacturer specifi cations or Foundry Service specifi cations: 1. Coating with insulating varnish 2. Treatment with fi ber-glass tape 3. Intermediate layers made of glass fabric laminate or Mica

BONDING

Preparation of the furnace coil for bonding Strapping of the furnace coil and adjusting

of the height dimension Bonding of all components with the Vac-Top® procedure

COVERING

Application of the protective coat Induction Safe® Sealing and insulating of power and

water connections Final inspection with test record Free storage

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INDUCTIVE HOLDINGChannel inductors are different from crucible furnace coils in their effi ciency and construction. In the sector of iron casting they are mainly used for holding and pouring. The construction of channel inductors is made up of the transformer coil, the transformer core, the protective cover and the housing. Our services include the maintenance and production of all mechanical components as well as the replacement of the furnace control system and all other electrical components.

Arrival of the inductor Preparation of an arrival record and

analysis of damages Preparations for disassembly

Disassembly of all components Repair and refurbishing Preparations for assembly and lining

Assembly of all components Insulation and pressure test of the inductor Creation of the test record Free storage

INDUCTIVE HEATINGInductive heating includes numerous applications and materials. The most frequent applications are found in induction billet heaters with one or more inductors. Special units tailored to workpiece contours are another sector. This requires an in-depth knowledge of electrical engineering and an extensive vertical range of manufacturing.

Special coil for the manufacturing of wheels for private and commercial vehicles

Special coil for the aerospace industry

Forging inductor for ingot heating

Special coil for the aerospace industry

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INNOVATIVE HOLDING TECHNOLOGY

Holding and storing molten metals is an essential production process for many foundries. It may be done in heated or unheated power units and is availbable for capacities of up to 150 t of cast iron.

Exploring new horizons and examining “longstanding” approaches – those are the challenges we enjoy. Being innovative, we have developed a new generation of holding furnaces and put them into operation. As the leading manufacturer of ladle and drive technologies we have merged this potential with our know-how in induction technology

The first holding furnace for steel casting with a revolutionary drive concept was the first result. This technology will enable you as our customer to control the furnace manually or with an electric or air pressure drive. Modular designs that are easy to maintain and a reliable inductor technology in energy-efficient implementations will be the plants of the future.

65 and 85 t forehearth, hydraulic cylinder used for tilting

Drive consisting of a planetary gear unit, type RSD 110 V, optionally with our two-tiered finger coupling and an electric motor or for manual tilting

Forehearth for 5 t of liquid metal, can be moved on rails, with modular design for a fast exchange of the furnace vessel

A classic cupola furnace operation includes a metal collector that contains a heated as well as an unheated installation. As a system supplier we manufacture both types of installations in various dimensions and designs. High-quality, temperature-resistant materials make a furnace vessel that has a long lifetime, free from warping, ensuring a long service life for the refractory lining. Our flexible design variables will allow you great freedom in designing a furnace for your particular operation demands and metal qualities. Our emergency concepts will provide for a complete emptying in cases of power failure – thanks to different drive concepts.

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Vacuum Systems Technology

High End Technology made by Foundry-Service Vacuum induction melting - that is high end technology for premium products, such as products of the aerospace industry. Under exclusion of the external atmosphere and under special pressure conditions, particularly pure, homogenous and highly efficient metals can be produced by our customers

A great measure of competence, experience and technology is required for the insulation and production technology in a vacuum. Therefore, a special insulation material was developed which ensures changed expansion characteristics and the mechanical strength of the insulation in a vacuum.

This is an important part of our high end technology:

VAC-TOP plus® Our references show that we are a highly estimated and reliable partner in the field of high technology.

VACUUM TECHNOLOGY SERVICE & QUALITY

For our company, service means 24/7 availability and services all over Europe. Our highly qualified and motivated team will ensure a fast restart of operation for your plant in case of damages or after a revision. Our phone number in the event of damage +49 (0) 23 72 55 98 0, but for all your other requests, too, of course. We will check your plant according to our check list as well as on the basis of thermographic images and we will prepare a furnace record for a CV of your plant.

MAINTENANCE, TESTING AND CONSULTATION

FREE STORAGE OF COMPONENTS

24/7 AVAILABILITY FROM ANYWHERE IN EUROPE

LOCAL ASSEMBLY

PREVENTIVE MAINTENANCE

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TEST PROCEDURESEndoscopic Examination

For an impression of the cooling channel and its soldered and welded joints, all copper hollow profiles may be examined with an endoscope to detect cross-sectionalchanges and deposits or tears inside the profile.

The endoscopic cooling channel examination is recorded on video, and the customer can view and comprehend any point of the examination.

Hot Compression Test

Under operational conditions hot compres-sion strength tests are performed for all crucible furnace coils after cleaning of the metal. In that way any capillary cracks may be localized that cannot be found in the cold pressure test.

The test is run at a water temperature of approx. 85°C and a pressure of 15 to 20 bar for twelve hours and documented.

Helium Leak Rate Test

After the repair, all induction coils are subjected to a vacuum leak rate test. During this test step, even smallest leaks as well as any capillary cracks that were not detected during the hot compression test are localized through the use of helium.

Another material structure test will be run for any sites localized by this procedure, to make sure that this is only a local porous site in the material.

Material Structure Test

An independent institute performs a material structure test of the copper profile. The results of the tests are much more than a mere appraisal. For the thorough analysis is an opportunity to draw conclusions as to the reasons for the wear of the coil. That knowledge, coupled with the long- standing experience of the operator, makes it possible to tell afterwards whether repair measures of the past were not performed properly or whether the copper profile material has been damaged.

High-Voltage Test

During the final inspection of the induction coil the dielectric strength of the insulation is checked with a high voltage detector. The test spectrum is performed at up to 6,000 V according to manufactu-rer specifications and recorded.

X-Ray

The necessary radiographic test of weld seams is conducted with the help of X-ray films and an X-ray tube. This is done particularly for vacuum coils and it is per-formed by an external service provider that is extremely reliable. With X-ray technology, especially pores and tears in the weld seam can be detected. The radiological findings are documented in a test report.

Final Inspection

Each component is measured and checked at all trouble spots prior to delivery.

This includes the labelling, measuring and examination to see if its state complies with the order. After the final inspection an examination report is prepared and provided to you.

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EXCLUSIVE FOUNDRY PRODUCTSUPGRADES & MODIFICATIONS

Our longstanding experience in the repair and maintenance of induction plants has led to numerous products and procedures. We must take a broader view to achieve our highest goal – optimum quality. The result must always be an improvement of the product, so we can ensure you a high availability and occupational safety. With an eye for details and great attention to a careful performance we tackle any weaknesses of your plant, constantly improving quality for you.

Vac-Top®

EA special resin-hardener combination guarantees a high-strength adhesive bond that is electrically nonconductive.

The design of the insulation technology ensures the escape of moisture, such as steam, and through the interior overlapping segments it increases the creepage current distance, so insulation defects can be avoided.

Together with our outer protective covering, InductionSafe®, we accomplish a fast drying pro cess of the refractory ceramics after a coil exchange or the application of a new refractory lining.

Induction Safe®

Our outer protective covering for all medium and mains frequency induction coils will guaranteee you: 1. Outstanding steam permeability as compared to conventional fiber rmats 2. High temperature resistance against molten metal splashes of up to 1,680°C 3. Prevents the deposit of conductive metal dust in the turns of coils 4. Compressibility, for a constant contact pressure of the magnetic yokes on the furnace coil 5. Absolutely no health risks for staff members

Trust the original. It can be used universally, it has been tested in practice and foundries cannot do without it.

Diro-Tech® Our unique aramid fibers with their remarkable features:

1. Not compressible, to ensure a constant contact pressure of the magnetic yokes on the furnace coil 2. Exceptional mechanical strength against damage, thus ensuring a long-lasting protection of the transformer laminations of the magnetic yokes 3. 8-year warranty on reusability of the aramid fibers

In connection with our multi-layer Mica insulation we will guarantee a long lasting protection of your furnace coil against insulation defects against the magnetic yoke.

Special cord for slat coils Glass fabric laminate segments for slat coils Segment design for medium frequency coils Conversion to VA cooling coil

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PRODUCT PORTFOLIOSpare parts are a factor that makes a great difference in a company‘s cost structure.In the event of damage the time factor is a decisive criterion for your company’s sustained efficiency.

What makes us distinctive is our ability to procure, repair or manufacture numerous plant components for you. The challenges we meet every day include minimizing your downtimes and enabling you to restart production as soon as possible. We have spare parts in storage at all times, so we can provide you with plant components you need as soon as possible. Our customer hotline:+ 49 (0) 2372 55 98 0 is available to you 24 h / 7 days a week

Magnetic yoke in an air or water-cooled version Choke in an air or water-cooled versionPower cables in air or water-cooled versions Transformers in air or oil-cooled versionsInductor coil on transformer core Capacitors

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LADLE TECHNOLOGYThe wide range of treating, transporting and pouring of molten metal takes center stage in the process workfl ow of a foundry. Metallurgical requirements will cause you as foundry operators to create more and more specialized geometries and processes to produce the requested qualities.

From standard ladles to high-end products in terms of inter-linking processes with unique ladle shapes, our products will enable you to meet those requirements.

The numerous different ladle systems are matched by countless special solutions for metal treatment, emergency emptying systems, railbound transport installations, heated and unheated forehearths, ladle heating stations, and special machine construction.

Our ambitions and experience and our numerous patents enable us to manufacture the perfect product for your requi-rements and install it at your plant. Our cooperation with the government agency for occupational safety, the trade associa-tions and the VDMA, together with a complete documentation, including a declaration of conformity and CE labelling will guarantee that you receive a safe product.

INSPECTIONS AND REPAIRS IN HEMER ACCORDING TO DIN EN 1247, INFORMATION 209-018- BGI 601 AND DGUV 33/34

INSPECTION AND DOCUMENTATION

TRAINING MEASURES FOR POURING LADLE VISUAL INSPECTION

POURING CRANE LADLES UP TO 100 T & STEEL POURING LADLES UP TO 350 T

TREATMENT LADLES & DRUM LADLES

SPECIAL POURING LADLES WITH SPECIAL BRACKETS

TRANSPORT CONTAINERS FOR LIQUID ALUMINUM

DRIVE TECHNOLOGY

ECCENTRIC AND PLANET OIL BATH GEAR UNITS(DRIVES BETWEEN 500 KG AND 100 T)

LADLE HEATERS, GAS AND OIL HEATING

MOBILE & STATIONARY EMERGENCY COLLECTION SYSTEMS

WIRE FEEDING TECHNOLOGY

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POURING CRANE LADLES UP TO 100 T & STEEL POURING LADLES UP TO 350 T

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1.0 t crane pouring ladles 70 t crane pouring ladle

Hinged heat shield Planetary gear unit RSD 140 V Transmission SG 978 Optionally switchable for manual or electric drive Air pressure drive with control unit and safety control

2.0 t teapot spout ladle 40 t and 59 t crane pouring ladle

Hinged heat shield Planetary gear unit RSD 180 V Optionally switchable for manual or electric drive Electric drive with frequency converter control & radio remote control Removable treatment lid

1.5 t drum ladle 60 t steel pouring ladle

Exchangeable double plug

STANDARD & LARGE LADLES

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SPECIAL LADLES MG TREATMENT LADLES

The treatment of molten metal is a process performed with various technologies. They include the Tundish cover process, wire feeding as well as treatment ladles and converters. We engineer and manufacture the equipment required for these procedures. Going easy on resources through a high effi ciency of aggregates and minimizing production costs is always paramount. In all of this we make sure that the high quality of the treated metal is ensured.

3.5 t Pouring ladle for casting machine

Refractory knock-out device Special connection and receiving points Modifi ed pouring system

9 t C-hanger

Exchangeable ladles with various capacities Simple fi lling from the melting furnace

without interfering edges

1.0 t Resistance-heated ladle

Resistance-heated ladles for holding of molten metal

The treatment of molten metal is a process performed with various technologies. They include the Tundish

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Patented pouring ladlewith hinged hanger

Hanger release withoutthe use of the gear unit, thus minimizing wear andtear of the gear unit and work for staff membersPatent since Nov 08, 2007

Patented pouring ladlemade of fi ber composite material

Extreme difference in weight – factor 1/7 as compared to conventional steel designs, all shapes and geometries possiblePatent since Jan 01, 2005

Patented pouring ladlewith double wall

Highly insulating ladle:Utillization of a basic holder with several inlays for different fi lling volumes and metal alloysPatent since Oct 04, 2007

PATENTS & SPECIALTECHNICAL FEATURES

Patented transport lockingFor forklift ladles (patent since Jul 24, 2014)

Ladles used to transport molten metal with forklifts must be protected so they don’t slip down from the truck forks unintentionally.

100% safety according to DIN EN 1247 Automatic, self-locking system Can be rotated, swivelled and tilted at 360° Can be retrofi tted to all existing ladle systems

Patented transport lockingFor forklift ladles

Ladles used to transport molten metal with forklifts must be protected so they don’t slip down from the truck forks unintentionally.

Innovation, creativity and courage are the driving forces that motivate us to develop new products and to improve existing ones. Generating added value for our customers, whether in increasing productivity, improving occupational safety or handling conditions for individual staff members, we always question all areas and examine them permanently.

Our numerous patents refl ect our customer closeness, our awareness of weak spots and a potential for improvements. Together with you as operators we create the platform for manufacturing products that you will not want to do without.

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DRIVE TECHNOLOGYThe drive is the most important component of a pouring ladle – for precise and effi cient casting. With our highly effi cient planetary gear units from the RSD and PG series we can manually cast ladle volumes of up to 150 tons of cast iron by means of back gears. Through the use of double-walled planet carriers and tempered ring gears we can achieve torque values that ensure a long service life and a less strenuous operation.

Our modular system “I-Drive” allows for a combination of each gear unit with a motor drive. By means of our multiple fi nger coupling you can optionally operate your pouring ladle with a manual or a motor drive. Besides our gear unit series SG, PG and RSD we can manufacture, repair and maintain all types of gear units.

On our test stand for gear units all gear units are tested and documented according to DIN EN 1247. As your supplier we only use original compo-nents, so we can ensure you a permanent maximum quality and safety.

Our gear unit series RSD is a consistent further development of existing gear units on the market. Some weak spots were analyzed and eliminated by our new development with the RSD gear unit.

The gear unit features an outstanding effi ciency, a modular design and a versatility without compromise. Double-walled planet carriers, specially tempered ring gears and double bearings will provide you with a tool that is unique on the market.

Our high-performance gear unit RSD 180 V takes our tried and tested reliable gear unit series to a new dimension. This gear unit enables us to operate large ladles or holding vessels of up to 60t without a back gear.

We can proudly say that our newly developed gear unit series has created a new benchmark in all foundries and steelworks since 2005. That enables us to grant you up to 5 years warranty on our product RSD.

optionally operate your pouring ladle with a manual or a motor drive. Besides our gear unit series SG, PG and RSD we can manufacture, repair

On our test stand for gear units all gear units are tested and documented according to DIN EN 1247. As your supplier we only use original compo-nents, so we can ensure you a permanent maximum quality and safety.

SG 179 220 Nm 836 Nm i = 37 up to 1.0 t

SG 180 500 Nm 1,650 Nm i = 50 up to 3.0 t

SG 181 800 Nm 3,440 Nm i = 55 up to 3.5 t

SG 182 3,000 Nm 6,000 Nm i = 81 up to 8.0 t

SG 183 3,500 Nm 12,500 Nm i = 138 up to 10.0 t

Gear type Nominal and output torque

Max. output torque

Transmission ratio

Ladle size

RSD 60 V 1,150 Nm 1,380 Nm i = 51.8 up to 2.0 t

RSD 80 V 1,800 Nm 2,760 Nm i = 44.6 up to 5.0 t

RSD 110 V 10,500 Nm 16,800 Nm i = 139 up to 12.0 t

RSD 140 V 32,000 Nm 51,600 Nm i = 203 up to 30.0 t

RSD 180 V 66,400 Nm 100,800 Nm i = 588 up to 60.0 t

Gear type Nominal & output torque

Max. output torque

Transmission ratio

Ladle size

PG 323 1,600 Nm 4,800 Nm i = 45.56 up to 5.0 t

PG 324 5,000 Nm 15,000 Nm i = 138 up to 12.0 t

PG 325 20,000 Nm 40,000 Nm i = 204 up to 25.0 t

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BACK GEARSOur back gears from the SG series are a reliable product for large dimensions. Ladle sizes of up to 150 t holding capacity can now be moved manually easily and safely. Our fi nger coupling with 2 or 3 levels lets you decide if you want to operate the ladle manually or with a motor.

All interlocking elements where the pin or hollow shafts are inserted are interlocked with a splined shaft according to DIN 5480. The double bearing design and the specially tempered interlocking elements ensure a fl awless operation even under the roughest conditions. With these drives you will move the greatest challenges precisely, just like those famous Switch watches.

Bracket lock

Back gear type SG 914

Trunnion ofthe ladle Gear unit type

RSD 110 V

Gear type Output torque Transmission ratio Ladle size

SG 914 30,000 Nm i = 2.5 : 1 up to 35.0 t

SG 978 88,500 Nm i = 4.0 : 1 up to 65.0 t

SG 1017 125,000 Nm i = 4.0 : 1 up to 110.0 t

SG 1073 250,000 Nm i = 4.0 : 1 up to 150.0 t

High-End I-Drive Gear Systemconsisting of:

Transmission SG 1073 Gear unit type RSD 180 V 2 pc. I-Drive Base Electric Drive Air Drive 3 level fi nger coupling for optional

operation with Electricoder Air Drive or manually

I-DRIVE GEAR SYSTEMSWith our newly developed I-Drive gear system we can fl exibly operate any ladle type with any eccentric or planetary gear unit with a motor. This allows you to choose either the electric drive or the air drive system. We use our two or three level fi nger coupling for the motor drive in both applications. This enables you to operate the ladle either manually or with the motor drive, as you choose.

I-Drive Base

Electric-Drive

Air-Drive3938

Two level fi nger coupling

INTELLIGENT DRIVESIntuition and precision make the difference for a good product. Our proportional drive that is based on a frequency control system will allow you to use that intuition. With our radio remote control you will always move at a safe distance and with an optimum fi eld of vision.

Our joystick control will let you fi nd your optimum speed at all times. The modular system “I-Drive” will allow a retrofi tting on existing drives at all times.

You can choose either an electric motor or an air motor. Depending on local conditions with regard to existing media and the casting environment, we can drive your ladle.

When you use the air pressure system you will have a simple and robust medium as well as proportional controls without any additional aggregates. That way you can use various casting speeds intuitively. Our modular system I-Drive can be used to install this on new and existing ladles.

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TESTS & TEST PROCEDURES Supersonic Technology Supersonic technology allows for an effective and at the same time economic non- destructive weld seam testing. Even with wall thicknesses of more than 15 mm it yields excellent test results. A lack of fusion in the weld seam between the welding deposit and the parent metal can be recognized clearly and localized. A supersonic test conducted according to the technical bulletin AD 200 is always documented in a test report.

Magnetic Particle Testing Magnetic particle testing is used to localize tears in or near the surface of welding seams and materials. This test procedure delivers much better results with reference to tears than a red-white test. We use this procedure at our plant and locally at our customers’ plants during the DGUV test.

Test Stand for Gear Units DIN EN 1247 contains clear rules about the testing of ladle gear units. It says that the dynamic self-locking effect of the brake unit must be checked at least every 2 years. It must be performed on a test stand, and the examination data have to be documented. This is due to the fact that a turn of the ladle when it is filled or an unintentional tilting of the crossbar constitute a great risk

Examination of pouring, transport and slag ladles according to DGUV and repairs according to DIN EN 1247, Information 209-018- BGI 601 and DGUV 33/34. A distinction is made between visual/functional tests and a main test. It includes a status assessment of the equipment (ladle) with reference to safety and functional features. During operation, under great stress, the operator must concentrate on the casting. It is therefore hardly possible to recognize defects or wear and tear, because that requires an objective evaluation of the current and the ideal status.

Our advantage lies in the fact that we test your tools free from production constraints and always according to current legal requirements, showing and documenting defects. As a certified company and manufacturer, we are perfectly equipped to ensure you optimum occupational safety. The exclusive use of original components will guarantee that you get reliable and safe tools.

We can perform any tests with our mobile team at your plant or you can send us your ladle. No matter how you use our services, we will always guarantee you a consistent quality.

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Your ladle must have been preheated and dry so it can be used in optimum ways. Occupational safety is essential in this respect. If the ladle lining contains moisture, this is an unpredictable safety hazard when it is fi lled with molten metal.

At the same time the service life of the ladle lining is reduced, if drying and preheating are not performed as prescribed by the manufacturer.

Our ladle heaters have been designed for standing and lying ladles as well as for tilted ladles. We can implement various processes with our controls:

Heating Heating and drying Heating, drying and holding

Our heating stations are an energy-saving, fl exible and reliable companion that provides you with optimum metal quality and service life of your refractory lining.

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EMERGENCY EMPTYING SYSTEMS

In cases of damage, the most important safety feature is the emptying of molten metal still contained in crucible and channel furnaces and forehearths, in order to minimize accidents and material damage. Usually the metal is conducted to an emergency pit where it solidifi es. It must later be removed at great expense.

Our concepts provide for optimum safety of humans and plants, while the molten metal is kept usable at the same time.

We have highly insulated emergency emptying systems for the purpose, to receive the molten metal, so it can solidify in batches compatible with your furnace system.

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CORED WIREEQUIPMENT

Design of a Treatment Cage

Using cored wires in foundries has become a proven procedure that is generally accepted. The process is precise and reproducible and it can be documented sustainably. Through the setting of various parameters the cored wire allows for a high specialization tailored to your operational conditions and metallurgic requirements during production.

Our wire-feeding equpiment features a simple opera-tion, great reliability and fl exible adaptation to your company’s requirements. We can meet all your requirements, from a simple equipment, consisting of a simple wire-feeding device with a control, to a fully automated process with a traversing carriage and closed cages.

As a system manufacturer we can perfectly plan, design and produce the symbiosis between the ladle and the wire-feeding equipment. We have the whole process in mind – from the melting furnace to the pouring station – so we can achieve optimum results for you, which is your advantage.

CORED WIREEQUIPMENT

Design of a Treatment Cage

Using cored wires in foundries has become a proven procedure that is generally accepted. The process is precise and reproducible and it can be documented sustainably. Through the setting of various parameters the cored wire allows for a high specialization tailored to your operational conditions and metallurgic requirements

Our wire-feeding equpiment features a simple opera-tion, great reliability and fl exible adaptation to your company’s requirements. We can meet all your requirements, from a simple equipment, consisting of a simple wire-feeding device with a control, to a fully automated process with a traversing carriage and closed cages.

As a system manufacturer we can perfectly plan, design and produce the symbiosis between the ladle and the wire-feeding equipment. We have the whole process in mind – from the melting furnace to the pouring station – so we can achieve optimum results for you, which is your

Our wire-feeding equipment can be used in many ways.It can be operated with cored wire betwee 9 and 16 mm, offering a combination of the following advantages:

Extremely compact design (620 x 880 x 640 mm) Two driving toothed wheels made from hardened materials Variable guide rollers for various wire dimensions Double monitoring of wire slipping Modular design to enable construction of multiple-line wire coiling systems

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DOCUMENTATION3D Model Visualization We use 3D model visualization simulations of the feasibility of a project in advance for you to detect interfering edges, so a speedy startup can be ensured as we implement the project. At the same time the display allows for a real view of the product, so you have opportunities for changes and special requests. By connecting this with our FEM calculation we accomplish a targeted design of the component, providing you with a tool that will immediately be accepted at your plant.

FEM Model of a Pouring Ladle The finite element method is used to calculate component stress factors, strains and deformations with respect to each new ladle. This is to make sure that each of our products achieves maximum safety and longevity. This is especially helpful in case of requirements that are difficult to calculate, because of weight minimization or volume increase, because it allows us to provide you with reliable information about the materials to be used and the design.

EU-Compliant Technical Documentation European guidelines and their national realization regulate the manner and extent of technical documentation. On that basis, we document and check each machine and installation. We can perform this service locally for you at your plant if you lack docu-mentation for your plant engineering or your documentation is faulty. Regardless of the type of equipment you will always get a documentation on the basis of the latest guidelines, standards and regulations.

LOCAL TRAININGBenefit from our technical knowledge and take advantage of your regular training opportunities. Our cooperation with the government agency for occupa-tional safety, the trade associations and the VDMA will guarantee that you always get current information. Technical trainings will be tailored to your personal desires and requirements, so you will have optimum and sustained results. We can conduct the training at your plant, at the offices of professional associations or at our facilities.

Our training deals with ladle and induction technology. We pass on basic knowledge about plant engineering as well as occupational safety.

Induction Technology: Safe handling of crucible induction equipment Maintenance and error analysis

Ladle Technology: Visual inspection of pouring ladles

Take advantage of our competence and increase your occupational safety and productivity by operating your plant engineering safely and efficiently.

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WHAT MAKES US UNIQUE ISWE UNDERSTAND YOU

Legal noticePublished by: Foundry Service GmbHEditor: Stefan Brands

© COPYRIGHT 2016 – All content of this publication (text & images) is subject to German copyright law. The reproduction, editing, distribution and any kind of use of such contents beyond the limits of copyright law shall require the written approval of the author or originator – Foundry Service GmbH.

Foundry Service GmbHSonnenblumenallee 12D- 58675 Hemer

Phone +49 (0) 23 72 / 55 98-0 Fax +49 (0) 23 72 / 55 98-77info@foundry-service.de www.foundry-service.de

SONNENBLUMENALLEE 1258675 HEMER / GERMANYPHONE +49 (0) 23 72 / 55 98-0 F O U N D R Y- S E R V I C E . D E

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2017

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