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Category Archives: MAGMA

Optimization of the Shooting and Curing Process for a Complex Core

Figure 1. First Core Blowing Test. The bottom of the core collapsed due to a lack of strength.

Figure 1. First Core Blowing Test. The bottom of the core collapsed due to a lack of strength.

Brazilian steel giant Usiminas recently introduced the new foundry core making simulation software MAGMASOFT® as part of their strategy to establish robust designs and processes for their core production line. The first project on which this software was utilized was already in progress at that time.

The main goal was to optimize the process conditions for the existing tooling layout. This core, called the thin waist core, represents some of the biggest challenges for Usiminas core production: its length (920 mm), substantial changes in the sand flow direction during blowing, the need to fill certain parts of the core through counter-flow and big variations in the cross section within the core.

First trials showed problems with the process, which led to a complete collapse of the lower part of the core. The core blowing and curing steps for the PU coldbox process were analyzed, making it possible to draw preliminary conclusions regarding the existing defects.

Figure 2. Curing Gas Concentration. The curing gas does not penetrate into the core to the same extent everywhere.

Figure 2. Curing Gas Concentration. The curing gas does not penetrate into the core to the same extent everywhere.

The lack of core strength was related to a poor curing process. The first simulation (Figure 2) already showed that the problematic regions experienced only very low curing gas concentrations during gassing, which was the root cause for the failure.

On the production line, various process conditions such as the curing and purging times and gassing pressure were changed. These attempts provided better results (Figure 3). However, a perfect core could still not be produced. The further analysis with MAGMASOFT® focused on the evaluation of the local concentration of adsorbed curing gas, as it shows the regions where the catalyzing gassing agent cannot activate the chemical reaction. This result clearly demonstrated that only a very small quantity of catalyst was available for accelerating curing in the defect regions (Figure 3).

Figure 3. Core Blown with new parameters in comparison with the local concentration of adsorbed curing gas. The problematic area corresponds exactly with low concentrations in the simulation.

Figure 3. Core Blown with new parameters in comparison with the local concentration of adsorbed curing gas. The problematic area corresponds exactly with low concentrations in the simulation.

Evaluating simulated curves for the gas mass flow through the vents made it clear that the catalyzing gas was not reaching the critical area. The open venting cross section of the top and central vents was allowing the gas to escape before it reached the bottom of the core.

Instead of making costly modifications to the core box, Usiminas determined that a possible – and simple – solution was to close some vents in the top and center regions, in order to increase the gas concentration in the bottom. However, it was clear that these changes obviously would also influence the core blowing step.

The optimization led to a considerable increase of the curing gas concentration in the lower regions of the core (~36%) (Figure 4). Also, the amount of adsorbed curing gas increased in comparison to the original project. Applying these modifications, Usiminas produced another core, which did not show any gassing defects. Since the venting area was reduced, some filling defects were present, as expected.

Figure 4. Total gas mass flow through the lower vents. The change in mass flow becomes clear. Removing some of the upper and middle vents resulted in a 36% increase in the gas escaping through the lower vents.

Figure 4. Total gas mass flow through the lower vents. The change in mass flow becomes clear. Removing some of the upper and middle vents resulted in a 36% increase in the gas escaping through the lower vents.

Having solved the curing related defects, a further core blowing analysis was carried out. The simulation results showed a very good match between the real defects and areas of low packing density. The flow animation also showed that the problems occurred because these areas had to be filled by a counter flow of the sand (Figure 5).

Another characteristic of the defects was that they all occurred next to the parting line of the core box.  Some of the defects showed a smooth surface, indicating that the sand had been removed by a strong air flow. The core blowing simulation results supported the Usiminas conclusion that an improper sealing of the tool was the root cause for these defects. Air could escape with high speed through the parting lines, resulting in the defect formation.

This hypothesis was tested using a silicone rubber band to obtain an improved sealing of the relevant areas of the tool. With this modification, a new core was produced which was absolutely free of any defects.

About software for casting process simulation

Casting process simulation software considers the complete casting process including mold filling, solidification and cooling, and also provides the quantitative prediction of mechanical properties, thermally induced casting stresses and the distortion of cast components. Simulation accurately describes a cast component’s quality upfront before production starts, thus the casting layout can be designed with respect to the required component properties. This results in a reduction in pre-production sampling, but also the precise layout of the complete casting system leads to energy, material and tooling savings for the foundry.

The range of application of MAGMA solutions comprises all cast alloys, from cast iron to aluminum sand casting, permanent mold and die casting up to large steel castings. The software supports the user in component design, the determination of melting practice and casting methodology through to mold making, heat treatment and finishing. This saves costs consequently along the entire casting manufacturing line.

During the last 10 years, the use of casting process simulation has become a valuable business asset for many foundries worldwide. MAGMA5 constantly expands the capabilities of casting process simulation and will further accelerate the acceptance of this technology, in the future.

About Usiminas

With 50 years of operation, Usiminas is the leader in the Brazilian flat steel market and one of the largest steel companies in Latin America. It has a nominal capacity of 9.5 million tons of steel per year. Usiminas Mecânica is a leading provider of capital goods and services to the steel, railway, mining, automotive, energy, petrochemical, marine and infrastructure industries in Brazil. With recent substantial investments, the foundry of Usiminas Mecânica has become one of the largest manufacturers of both small and large steel castings in the country. The yearly production capacity is 30,000 tons, representing about 10% of the projected production in Brazil.

About MAGMA

MAGMA offers comprehensive solutions to the metal casting industry, casting buyers and casting designers worldwide. The MAGMA product and service portfolio includes the powerful modular simulation software MAGMASOFT®,with the newest release MAGMA5, as well as engineering services for casting design and optimization.

Today, MAGMASOFT® is used throughout the metal casting industry, especially for the optimization of cast components in automotive and heavy industry applications.

MAGMA Giessereitechnologie GmbH was founded in 1988 and is headquartered in Aachen, Germany. A global presence and support are guaranteed by offices and subsidiaries in the USA, Singapore, Brazil, Korea, Turkey, India and China. Additionally, more than 30 qualified partners represent MAGMA around the world.

For more information on this release, please contact:

Christof Heisser
President
MAGMA Foundry Technologies, Inc.
10 N. Martingale Road, Suite 425
Schaumburg, IL 60173
Phone: 847-969-1001 ext. 225
Email: cheisser@magmasoft.com
Web: www.magmasoft.com

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MAGMA, Sea Scouts, Castings and Sea Shells…Foundry Market Leader Teaches Next Generation

Steve Sikorski from Magma (far left) led the teaching experience for the Racine, Wisconsin Sea Scouts, as they learned about metalcasting.

Steve Sikorski from Magma (far left) led the teaching experience for the Racine, Wisconsin Sea Scouts, as they learned about metalcasting.

In March 2013, representatives from MAGMA Foundry Technologies used the Foundry in a Box, donated by AFS, to teach the Racine, Wisconsin Sea Scouts, Ship 5750, about metalcasting.  Sea Scouting is a division of the Boy Scouts of America for young men and women between 14 and 21 years old.  The group focuses on developing future leaders through developing maritime skills, both on and off the water.  The Scout group devotes their summer activities to sailing and their winter activities to learning manufacturing skills to produce useful items.  Previous projects included land sailing vessels, a pig roaster and rebuilding engines for use in boats.Pour

During this past winter, the scouts focused on developing their metalworking skills by making wind vanes using welding, grinding, machining and plasma cutting technologies.  This project had all the Scouts excited about metalworking and it created a great opportunity to expose them to metalcasting technology, where Magma is the market leader in casting simulation and process optimization for foundries worldwide.

CleanThe meeting was kicked off with a short presentation about metalcasting and how this 6,000-year-old process relates to products the Scouts use every day.  The Scouts were then allowed to get started with a hands-on project, with each Scout creating a mold, melting the metal, pouring the casting and cleaning the castings.  Some Scouts used the standard patterns that came with the Foundry in a Box, while others were more adventurous and tried making their own patterns, one being sea shells. A final presentation was made, tying in this age-old process with advanced casting process simulation technology to show what occurred inside the mold during the making of the Liberty Bell casting.

For more information on this story, please contact:
Christof Heisser
President
MAGMA Foundry Technologies, Inc.
10 N. Martingale Road, Suite 425
Schaumburg, IL 60173
Phone 847-969-1001, ext. 225
Email  cheisser@magmasoft.com
Web    www.magmasoft.com

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Customers come to Spokane to buy castings and solve problems

Spokane Industries, a family-owned company established in 1952, is a steel foundry, metal products and precision castings facility of more than 240,000 square feet in Spokane, Washington.  Spokane Industries serves customers in many industries from aerospace, construction and agriculture, to transportation, aggregate processing and general manufacturing. Proud to be a family-owned company, many employees here are second and third generation who are personally and professionally committed to their customers. Customers are not just coming to Spokane to buy castings, but they are coming to solve problems. With that in mind, experience, expertise, effort and the latest technology, including MAGMASOFT® process optimization software, are used to differentiate Spokane Industries in the marketplace. Spokane strives to create quality products delivered on time and as a result, their customers’ businesses are more successful and profitable.

Antonio Melendez works on MAGMASOFT

Antonio Melendez works on MAGMASOFT®

The Spokane Steel Foundry Division is the foundation of Spokane Industries and is committed to staying on the cutting edge of technology, upgrading its facility to optimize production and enhancing quality control procedures. Spokane Steel Foundry has been serving commercial and industrial customers around the world for more than 50 years, still maintaining some of their original customers; some are still ordering castings from their original patterns.

Experiencing decades of steady growth, Spokane Industries operates an environmentally clean, well-managed and technologically advanced organization dedicated to meeting the needs of its customers. Today, the foundry’s output includes durable wear parts for impact crushers as well as a wide variety of high specification quality castings for the construction, mining, manufacturing, transportation, aluminum and defense industries, striving to meet the demand with each project.

By introducing MAGMASOFT® at the company, Spokane quickly saw how this software’s capabilities of simulating the entire casting process start to finish, was not only an invaluable engineering tool, but also a tool that impacted the entire business. CFO Ken Vorhees reported, “Having MAGMASOFT® has improved our ability to reduce the number of samples and bring quality products to market faster through meeting specifications, tolerance and metallurgy, most often on the first run.” Foundry Division President, Tyrus Tenold, adds, “This is a very powerful tool, giving us the ability to virtually see the entire casting process before we have invested significant time and materials. We now catch problems before they become problems. By the time we are ready to run the part, we have confidence we will have a quality part on the first run, in most cases.” Using the software to run detailed process optimization for the entire casting process enabled Spokane to catch process issues anywhere in the casting process before the first actual run. The software enables the engineers here to catch potential problems with a casting before the part even hits the foundry floor and resolve them faster than any competitor not using this technology.

Having now utilized its MAGMASOFT® license for 2 years, Spokane has seen a significant change in their entire casting process. Rod Grozdanich, Technical Director, states, “We use the software to help customers refine their designs as well as convert many of their weldments into castings. Being able to simulate the entire process helps a lot, in that regard.” The software being one of the foundry’s business tools has helped them support their selling point that they are more cutting edge and in a leading group of local vendors with the latest technology and equipment.

Antonio Melendez, Design Engineer, points out, “By having MAGMASOFT®, we find that our customers expect more of us. We are confident that we can deliver and have always lived up to and exceeded the challenges our customers have given us.” He adds, “It has become common that when we go back to a customer with a design change that effects them, costs them more money, like adding a riser, they want to know why. MAGMASOFT® gives us that credibility and additional technical support for our case.”

Spokane Employees Discussing MAGMASOFT’s benefits – Antonio Melendez, Design Engineer, David Jolin, Quality Assurance Manager, Rod Grozdanich, Technical Director

Spokane employees discussing MAGMASOFT’s benefits – Antonio Melendez, Design Engineer, David Jolin, Quality Assurance Manager, Rod Grozdanich, Technical Director

David Jolin, Quality Assurance Manager, says, “We do see both current customers and potential customers requiring that we run the casting through a solidification program. There have been times where we have been directly told that in order to be awarded a particular job, we need to show them simulation capability. We are seeing this as a requirement, more often nowadays.”

A big part of justifying the cost of the software was being able to go back and simulate past projects to make designs changes and improve the quality of the castings for future runs. Grozdanich says, “We found many jobs that we set up with our previous simulation software where we really couldn’t see the shrink, and now with MAGMASOFT®, we can see what’s happening and we can fix it. We had chronic instances with issues on jobs in the past that we just could not solve and with MAGMASOFT® we have been able to go in and fix them all.”

Simulating the entire process from design to finished part helps save time and money by creating all the changes and making all the mistakes virtually rather than during actual production. Melendez states, “We are trying to minimize the number of samples before releasing a casting for production. The idea is to do all the tweaking on the computer without spending money to pour multiple samples. This year, we have significantly reduced the number of samples and are more likely to produce a quality part on the first run.”

In addition to the ability to simulate the entire casting process, Spokane has found a solid partner in MAGMASOFT® by taking advantage of the resources extended to them as a user. “The user group meeting every year is a very good tool to keep us informed of new developments and get everyone up to speed on anything we feel we would like to improve upon. Peer-to-peer discussions on how we each utilize the software are invaluable,” Melendez says.

Of the four capabilities that make up Spokane’s license with MAGMASOFT®, namely filling simulation, solidification simulation, heat treatment and stress analysis, Spokane utilizes all these processes to the fullest extent, including macro segregation simulation. Grozdanich points out, “In the last 10 months, on the dozen or so new projects we have put out, all but one or two were quality parts on the first run. Our time to first quality part has therefore been greatly reduced.” Jolin adds, “Being able to simulate the entire casting process has significantly fixed our shrink issue, which was quite a struggle from my end before MAGMASOFT®.” Melendez offers, “One of the main advantages of the software is one can see roadblocks before they actually happen and can compensate for them, specifically with predicting the distortion of the casting and other issues that might arise before we actually build it.”

Søren Anderson of MAGMA shows Antonio Melendez, Design engineer at Spokane, some MAGMASOFT upgrades

Søren Anderson of MAGMA shows Antonio Melendez, Design Engineer at Spokane, some MAGMASOFT upgrades

In addition, the software helps gain understanding and provides clues to what can be happening when issues arise that initially don’t make sense. It’s proving to be a reliable troubleshooting tool by helping to gain clarity where there are issues that arise that are initially not understood. MAGMASOFT® is the missing link that helps lead to that solution, according to Spokane engineers. Antonio Melendez observes, “The software verifies what is going on, gives clarity and enables us to pass on not only an opinion, but provides credibility to support our opinion to our customer. The software is able to set particular processing parameters. For example, when pouring through a sleeve with a filter, there were scrap issues with the filters breaking. After doing some simulations and flows through that method, we could see that, for one ladle, we needed to use an inch and a half diameter nozzle, that way the flow is just right for this particular set up.”

Melendez adds, “Each casting is different, the number of iterations are different. It is more a question of how tough is the part. For example, if you have a part with isolated hot spots and you don’t have clear filling patterns, you are going to struggle. The advantage with MAGMASOFT® is you can see those trouble spots and focus on resolving the issues before creating the first sample. Even if you need to do 200 iterations in the right direction, that’s okay, because we are no longer shooting in the dark.”

At this foundry, it’s clear that their use of process optimization software is yielding benefits across the entire business environment, from design through material use, production through part validation and in differentiating Spokane Industries from its competition in the marketplace.  The result is more work being processed more efficiently, with the plant’s capacity utilization being much higher and more profitable, according to Spokane personnel.

For more information on this story, please contact:

Christof Heisser
President
MAGMA Foundry Technologies, Inc.
10 N. Martingale Road, Suite 425
Schaumburg, IL 60173
Phone: 847-969-1001 ext. 225
Email: cheisser@magmasoft.com
Web: www.magmasoft.com

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MAGMA5 5.2: Latest Release of MAGMA’s Casting Process Simulation Software Now Available

Schaumburg, Illinois (Chicago) –  With MAGMA5 5.2, MAGMA Foundry Technologies has recently released the latest version of its leading casting process simulation software with significant new and improved functionality. More than 160 improvements were implemented for the user in this new release of version 5.2.   The main focus of the development efforts was on increasing the efficiency in evaluating simulation results.

MAGMA5 5.2 now allows the direct comparison of up to four different project versions in the result perspective. Filling, solidification and stress results can be animated in a synchronized mode. A special highlight is the option to display the geometry and all MAGMA5 results in 3D stereo, using shutter or red/cyan 3D glasses and to store them as 3D images or movies. Various new tools facilitate a standardized result evaluation. 

New result criteria allow for a more effective evaluation of metal cooling and critical metal speeds during filling. The progress of feeding and porosity formation can be monitored and displayed continuously during the entire solidification process. A new criterion to predict cold cracks allows the user to find stress-related casting quality problems more quickly.

The implementation of user results further offers a powerful tool to compile user-specific criteria based on any MAGMA5 results. User results can easily be defined and created automatically during a simulation or subsequently in the result perspective.

Die casting users will appreciate an improved visualization of the process time line and extended consideration of the heat transfer conditions between die casting and die as a function of the local feeding conditions. Additionally, the MAGMAhpdc module now supports the assessment of the real casting temperature as a function of the current shot sleeve conditions.

All users will benefit from the new “resume point” capability, which allows flexibility in re-starting the simulation with modified die casting process conditions, based on the previous or next-to-last casting cycle. Sand casting processes can be resumed with different conditions at the end of any process stage. The automatic enmeshment of complex geometries is now further simplified by new enmeshment criteria and procedures.

Stress simulation results can be prepared for faster post-processing. For the quantitative assessment of casting distortion in the measurement perspective, it is now possible to compare the virtual measurement with the real part geometry.

Finally, with MAGMA5 5.2, a new database of riser sleeves, which was generated by ASK Chemicals, is now available.

 

About MAGMA

 

MAGMA offers comprehensive solutions to the metal casting industry, casting buyers and casting designers worldwide. MAGMA’s product and service portfolio includes the powerful, modular simulation software MAGMASOFT®,with the newest release MAGMA5 as well as engineering services for casting design and optimization.

Today, MAGMASOFT® is used throughout the global metal casting industry, especially for the optimization of cast components in automotive and heavy industry applications.

MAGMA Giessereitechnologie GmbH was founded in 1988 and is headquartered in Aachen, Germany. A global presence and support are guaranteed by offices and subsidiaries in the USA, Singapore, Brazil, Korea, Turkey, India and China. Additionally, more than 30 qualified partners represent MAGMA around the world.

For more information on this release, please contact:

Christof Heisser

President

MAGMA Foundry Technologies, Inc.

10 N. Martingale Road, Suite 425

Schaumburg, IL 60173

Phone 847-969-1001 ext. 225

Email  cheisser@magmasoft.com

Web    www.magmasoft.com

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Dotson Makes It A True Team Effort

Minnesota foundry includes multiple layers from their organization to decide on the right casting process simulation tool

Wide view of Dotson Iron Castings in action

Dotson Iron Castings in Mankato, Minnesota is an iron foundry that melts and pours 100+ tons of ductile iron castings daily, using 20X24 horizontal, high pressure, green sand molding machines. Products include over 3,000 different castings for over 300 customers in a wide range of applications including medical, transportation, agriculture, construction and recreation equipment. The raw casting weights here range from 2 to 50 pounds with typical production quantities ranging from 25 pieces to several thousand.

Dotson prides itself on engineering excellence, providing customers a higher total value with castings designed and produced in a highly automated, quick response foundry and machining facility.

Operating as a foundry for over 130 years, Dotson credits its success to satisfying customer needs by not only managing, but exceeding, their expectations. The goal is to provide customers with quality products in a fast, flexible, cost effective manner.

As a company best practice, Dotson includes its employees in making all important decisions that will impact not only the job of each of the individuals, but the foundry as a whole. Dotson has a program called, “The $10,000 Project.” As the name implies, any purchase made by the foundry of $10,000 or more is done through a detailed process involving the employees who will be most affected by the purchase of the product or equipment being considered.

Any product or project that costs over $10,000 must have a cross-functional group examine all viable options. Members of the group choose what they consider the best product or piece of equipment to help them accomplish their goals.  They then make onsite visits, make comparisons and do cost justifications.  With the information they have gathered, they then make multiple presentations to the group explaining the “what” and the “why” of the product, equipment or service they have chosen for consideration.

John Jaycox, Bradley Wiyninger, Jim Headington and E. Jay Zins discuss MAGMASOFT® at Dotson

When Dotson’s owner Denny Dotson and President /CEO Jean Bye wanted to expand their capabilities in terms of serving customers with solidification solutions, MAGMASOFT®, provided by MAGMA Foundry Technologies (Schaumburg, IL) was one of the many software packages considered. “We certainly are a foundry that differentiates ourselves on our engineering services and to do that you must have the right tools,” Jean Bye said. “We researched and explored our options for a few years before making the decision to purchase simulation software for the foundry,” Denny Dotson adds.

The $10,000 Project is a lengthy process with the participants sometimes making three or four presentations to support their argument. Deciding on the simulation software that best supported the needs of this foundry took a long time, due to the importance of doing numerous comparisons. When comparing the benefits of all the products being considered, “…it came down to weighing out the factors and deciding which ones would have the greatest impact on the overall foundry operation,” Bye stated.

When the $10,000 Project is complete and a decision has been made, nobody can say they weren’t onboard. “They might not have gotten their way,” Bye notes, “but they certainly understand all the reasons why the decision was made, because it was well thought out by the entire group.”

Dotson saw the addition of simulation software as more then just an engineering tool; rather it represented a smart business tool specifically designed to improve yield as well as positively impact sales. There was a lot to consider in the justification process beyond the product’s capabilities. Ease of use, speed of use, accuracy of results, presentation of these results, reputation of the provider’s company, customer care, quick response time from company representatives when there was a question or assistance was needed, as well as which company Dotson felt was more technologically advanced with new innovations. In addition, a significant benefit Dotson saw with simulation was the ability to identify jobs that would require some type of stress relief before actually making the tool or gating system. “It’s much more difficult to go back to the customer after the fact and tell them this is your cost, than it is before you cut the tool. There are always options before anything is created,” Engineering Process Manager Jim Headington points out.

“Moving from opinion or educated guess to a factual report supporting changes has made it quicker and easier to communicate the need for making changes with our customers,” adds Jay Zins, Control Manager at Dotson.

Live shot of Dotson in action

When discussing the impact simulating the process has on time to first quality part, Headington explains, “Time isn’t always the most important issue at hand. Cost and the integrity of the tool by the time you’re done with it are the real keys. When you find yourself adding material to a production tool, it’s never a good thing. Once you scab on that material, no matter how you put it on, you’ve really jeopardized the integrity of the tool. This is all now done virtually, instead of through trial and error.”

On one recent customer project, Dotson ran approximately 30 virtual iterations on a particular part. Not only did having the ability to simulate the entire molding process save a significant amount of time, being able to run a large number of iterations also helped them be sure that the quality of the part was not compromised. “Once in a while, on projects like this, we do 30 simulated iterations, simply because we now can,” Josh Jaycox, Quality Assurance Engineer adds.

While all new jobs at Dotson are run through MAGMASOFT®, retro jobs, especially the high yield jobs, are also now simulated. A significant part of the justification process was improving yield. When considering yield improvements, Dotson recognizes that the improvement in the first year will normally be significant, as they hadn’t run simulation before, whereas moving forward, improving yield would be less significant, as all new jobs are now run through the simulation and, as a result, are more efficient from the very beginning. “Running the software on a casting will also help us see that it may be possible to make a riser smaller, this will help in de-gating and reduce grinding time.” Jaycox said.

Sales and Marketing Manager Matt Schindle adds, “The benefit to the customer is that they know we are not going to build a tool, we are not going to spend a dollar of their money, until we have done the solidification on it. It gives us more credibility and it gives the customer reassurance.”

“It’s almost like having a third party in the room giving our observations credibility,” Bye adds.

Furnace at Dotson Iron Castings

Seeing the importance of being sure their foundry and their engineers have the tools to be the best they can be, Dotson found the addition of MAGMASOFT® to be a natural next step. When considering the in-depth justification process and the criteria involved in bringing a new product or tool into the foundry, they learned their decision regarding process simulation to be a great benefit to the company overall.  Dotson realizes customers now expect and rely on the fact that their parts are run through this virtual process with the end result being the highest quality castings possible.

Choosing MAGMASOFT®, Dotson believes all their performance and value criteria were met and, in many cases, even exceeded. MAGMA’s reputation in the world foundry market and their customer care program, as well as the added benefits of their training programs and annual user group meetings, help Dotson feel more confident in their partnership with MAGMA, according to Jaycox and Headington.

For more information on this story, please contact:

Christof Heisser

President

MAGMA Foundry Technologies, Inc.
10 N. Martingale Road, Suite 425
Schaumburg, IL 60173
Phone 847-969-1001 ext. 225
Email  cheisser@magmasoft.com
Web   www.magmasoft.com

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MAGMA Announces Two Certified User Achievements

Premier Aluminum and Hodge Foundry techs receive the highest level of simulation software competency designations from foundry market leader

Premier – Jason Lythjohan of Premier Aluminum in Racine, Wisconsin receives his MAGMA certification.

Schaumburg, IL – MAGMA Foundry Technologies Inc. has been a provider of proprietary casting process simulation software, MAGMASOFT®, for over 20 years.  More than simply providing software, MAGMA also shares its engineering expertise through its contract service group and comprehensive training programs. This extensive training program comprises several intensive course levels, where the users gain knowledge to better utilize the software from a functional standpoint, plus insights on practical approaches to applying the technology to their metalcasting process.

Currently, the highest achievable training level is the Certified MAGMASOFT® User.  There is a set of specific criteria the user must meet to be eligible to participate in the program and a list of objectives that must be met to receive the certification from Magma.

There are many benefits to completing the certification program, which aid not only the software user, but also the user’s organization and its casting customers.

Some of the key benefits include:

Hodge Foundry – Ian McNally from Hodge Foundry in Greenville, Pennsylvania receives his MAGMA certification.

  • Improved efficiency and more effective utilization of the software for speed to solution
  • Improved result interpretation and knowledge of root cause analysis
  • Gaining a greater understanding of how simulation applies to their organization and customer base in the areas of design, process, quality and overall costs
  • Enhanced communication internally and with their customers to reduce costs associated with program launches and casting quality
  • Establishing a mark of excellence that sets their organization apart from the competition, including those who already have MAGMASOFT®

In 2011, two successful users achieved the MAGMA Certification, namely, Jason Lythjohan from Premier Aluminum, LLC and Ian McNally from Hodge Foundry.

Premier Aluminum has opened a technology center for its customers and potential customers to come in and use MAGMASOFT® Simulation Software for the design and engineering of their castings.

Premier Aluminum, located in Racine, Wisconsin and part of Ligon Industries LLC, is an ISO 9001-2008 certified permanent mold aluminum casting and machining shop.  Premier has a reputation for partnering with its customers to find flexible and cost-effective solutions to a variety of product problems.

Hodge Foundry, founded in 1876 and located in Greenville, Pennsylvania, is an internationally-recognized specialty engineering foundry that manufactures high quality complex gray and ductile iron castings.

For more information on this release, please contact:

Christof Heisser

President

MAGMA Foundry Technologies, Inc. 10 N. Martingale Road, Suite 425 Schaumburg, IL 60173

Phone +1 847-969-1001 ext. 225 Email: cheisser@magmasoft.com Web: www.magmasoft.com

 Agency contact for MAGMA:

Wendy McCormick

Bernard & Company, Palatine, Illinois (Chicago) USA +1 847 934 4500 wendy@bernardandcompany.com

www.bernardandcompany.com

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Continental communicates with its subcontractors through MAGMASOFT®

Casting process simulation to automotive industry standards

Continental is one of the five biggest international automotive suppliers worldwide. The two group sectors, Automotive and Rubber, provide a range of products addressed to automotive trends in the areas of safety, environment and information. In 2009, the 143,000 employees in six divisions generated sales of approximately 20 billion euros (~$28B).

Cast components can be found throughout engine, brake system, body and interior components. For this reason, Continental, with its three automotive divisions, is one of the world’s largest consumers of castings. Continental does not produce the castings itself, but instead buys these parts in large quantities from outside vendors. In view of the great importance of these components in its products and systems, the Automotive Group devotes a great deal of attention to its cooperation with foundries. For Continental, it is vital that all suppliers reliably meet their quality standards and can guarantee secure processes. If production lines come to a standstill at Continental – or worse, at Continental’s customers – losses can quickly run into the millions.

 As a direct supplier to carmakers, Continental is in a sandwich position. The company must guarantee product and process quality to its customers and pass on these requirements to its own suppliers. Consequently, continuous audits of partners are used to assure a constant, sustainable productivity and to ensure the use of the most competitive technologies. The same applies to requirements for product and service quality, which must be highly cost effective, as well as comply with project deadlines.

 

Casting simulation as foundry selection criterion

When it comes to the quality of purchased castings, Mustafa Ata, Senior Expert Casting Quality, is in demand in Continental’s Automotive Group. He audits the foundries which supply Continental worldwide. “The quality requirements for castings, which are for the most part installed in safety-relevant areas of cars, are extremely high. The prevailing international standards are supplemented by internal group standards, e.g. with regard to service life, material strength, metallurgical properties (microstructure), machinability of the components and optical appearance,” Mustafa Ata said when describing what he expects from foundries.

From Continental’s point of view, a reliable compliance with this performance catalog cannot be achieved without the foundries using the latest casting technology and tools. In the case of safety components, the group requires its suppliers to use software for casting process simulation, to check the casting process and analyze the results with Continental before production starts. Continental also requires that their foundries be in a position to optimize the process if necessary.

 “Simulation is anchored as an important part of supplier communication. This means that in every casting project, product realization is supported from the very beginning by numerical simulation. We expect our suppliers to possess a simulation tool,” Ata noted, leaving no doubt in this regard.

 

From design to production – but not without simulation

 The casting development process begins at Continental. The design department designs the casting according to the automotive manufacturer’s requirements. The 3D data produced goes to selected foundries to enable the latter to simulate the casting process with suitable software. The simulation checks various factors that are critical for casting quality simultaneously.

 First, the simulation can determine whether the casting was designed in a casting-appropriate manner or whether the design department, in cooperation with the suppliers (simultaneous engineering), needs to readjust the design to permit standard-compliant parts to be reliably produced in a cost-effective casting process. Second, the simulation results can reveal whether, under the specific production conditions of the foundry, a stable, economical process can be established or whether changes need to be carried out.

 

Simulation result: production and delivery security

 As its final result, the simulation provides Ata with the certainty that the foundry can reliably produce and deliver a casting that meets the requirements at optimal costs. Without casting process simulation, such security could only be achieved with multiple casting trials and machining, at costs and project times that are no longer competitive in the automotive industry.

Simulation with MAGMASOFT® welcomed

In general terms, Continental allows its suppliers to choose which software they use for casting process simulation. But, most foundries opt for the MAGMASOFT® software from MAGMA Gießereitechnologie GmbH, which Ata welcomes for various reasons.

 MAGMA is the pioneer in casting process simulation software. As a software developer, more casting engineers work at MAGMA than in many foundries. Because of this, MAGMA is regarded as the worldwide market and technology leader and sets the standard in this field.

The simulation results provided by MAGMASOFT® are extremely realistic.

Empirical checks through real trial castings regularly demonstrate that the results correspond to a large extent with the observable properties of the cast components.

 “Simulation results from MAGMASOFT® are accepted as reliable by all parties involved in the production process. As a result, they form the basis on which designers, foundrymen and users can discuss component quality and process optimization, further developments and modifications,” according to Ata.

 MAGMASOFT® offers solutions for all casting processes and process steps. In doing so, the software covers every possible simulation situation which arises at Continental in the cooperation with foundries. Therefore, the partners do not need to deal with different applications.

 In the foundry, MAGMASOFT® users benefit from the simple operation of the software and the service of the provider, which meet the high demands of the automotive industry.

Continental considering using MAGMASOFT® itself

 Until now, Continental has only required that its vendors utilize casting process simulation software. However, Continental is now considering using  MAGMASOFT® itself. In this way, the design of a component could be checked for casting suitability immediately and the feedback loops shortened further. Simultaneously, communication with Continental’s development partners could be improved even more through the common “language” of simulation results.

About software for casting process simulation

Casting process simulation software considers the complete casting process including mold filling, solidification and cooling, and also provides the quantitative prediction of mechanical properties, thermally induced casting stresses and the distortion of cast components. Simulation accurately describes a cast component’s quality upfront before production starts, thus the casting layout can be designed with respect to the required component properties. This results in a reduction in pre-production sampling, but also the precise layout of the complete casting system leads to energy, material and tooling savings for the foundry.

The range of application of MAGMA solutions comprises all cast alloys, from cast iron to aluminum sand casting, permanent mold and die casting up to large steel castings. The software supports the user in component design, the determination of melting practice and casting methodology through to mold making, heat treatment and finishing. This saves costs consequently along the entire casting manufacturing line.

During the last 10 years, the use of casting process simulation has become a valuable business asset for many foundries. MAGMA5 now expands the capabilities of casting process simulation and will further accelerate the acceptance of this technology.

About MAGMA

MAGMA offers comprehensive solutions to the metal casting industry, casting buyers and casting designers worldwide. The MAGMA product and service portfolio includes the powerful modular simulation software MAGMASOFT®,with the newest release MAGMA5, as well as engineering services for casting design and optimization.

Today, MAGMASOFT® is used throughout the metal casting industry, especially for the optimization of cast components in automotive and heavy industry applications.

MAGMA Giessereitechnologie GmbH was founded in 1988 and is headquartered in Aachen, Germany. A global presence and support are guaranteed by offices and subsidiaries in the USA, Singapore, Brazil, Korea, Turkey, India and China. Additionally, more than 30 qualified partners represent MAGMA around the world.

For more information on this release, please contact:

 Christof Heisser

President

MAGMA Foundry Technologies, Inc.

10 N. Martingale Road, Suite 425

Schaumburg, IL 60173

Phone 847-969-1001 ext. 225

Email            cheisser@magmasoft.com

Web            www.magmasoft.com

Agency contact:

Wendy McCormick

Bernard & Company

847-934-4500

wendy@bernardandcompany.com

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North American MAGMASOFT User Group Meeting 2011

The entire group of MAGMASOFT users and the MAGMA staff gather on the grounds for a group photo

Schaumburg, IL –Removing Roadblocks to Success was the theme for the 2011 MAGMASOFTNorth American User Group meeting, held September 13-15, 2011 at Eaglewood Resort & Spa in Itasca, Illinois. One of the main purposes of the annual MAGMASOFTUser Group Meeting (UGM) is for MAGMA to provide its users with ways to be more successful using MAGMASOFT, the leading simulation software in the foundry market. MAGMA has learned that their users benefit greatly by gaining knowledge from each other as well as relying on the MAGMA engineers for technical support.

MAGMA annual user group meeting gather on day 1 for the general group session

 MAGMA looks to its customers to help them continue to improve and grow as an organization. MAGMA sees itself as an asset to their customers’ entire organization and wants to help them to not only utilize MAGMASOFT to its fullest potential, but to go beyond the engineering department and implement MAGMASOFT in their entire organization, i.e. in sales and marketing, production, and quality departments. The more areas in the customer’s organization where MAGMASOFTis utilized, the more productive and profitable their operations become, according to company president Christof Heisser.

Christof Heisser, President of MAGMA Foundry Technologies, Inc. welcomes the MAGMASOFT users to the 2011 North American User Group Meeting.

MAGMASOFT users addressed the group with their presentations.  Greg Miskinis from Thyssen Krupp Waupaca presented “How To Get Management to Write the Big Check.” Keith Pearl from Caterpillar South Milwaukee discussed “Utilizing MAGMASOFTin the Supply Chain.” Brodie Biersner and Sairam Ravi, both from the University of Northern Iowa, presented papers on mold instrumentation and simulation of veining defects using MAGMAapi, respectively. Lastly, Charlie Monroe from Caterpillar closed out the general session with his presentation entitled “Save Money Using MAGMAfrontier.”

In addition, three candidates, Ivy Courtney from Riverside Brass, Jason Lythjohan from Premier Aluminum and Ian McNally from Hodge Foundry gave their presentations for their MAGMASOFTCertification within the MAGMA User Group.

Steve Sikorski and Benji Johnson (seated at front table) both from MAGMA facilitate the non-ferrous breakout group discussion on “roadblocks”

After completing a questionnaire regarding different roadblocks during the general session, the 120 MAGMA users in attendance were split into one of four categories: HPDC, Non-ferrous, Steel or Iron. In these groups, potential roadblocks such as set-up and analysis of simulation, calculation times, hardware (memory, speed), capability (training) of users, immediate management, upper management, workload, communication issues with customers, as well as others were discussed in a peer-to-peer group setting, with attendees as well as MAGMA staffers providing possible solutions.

Matt Jacobs of MAGMA Foundry Technologies, Inc. facilitated the general sessions.

           The advanced use of MAGMASOFTand specifically its latest version MAGMA5was a recurring topic in the traditional small group breakout sessions.  In addition, guest speakers presented process and alloy specific topics, creating an environment for interaction between these technical experts, users and MAGMA staff. To close the two-day meeting, details of the anticipated version 5.2 and future developments were presented to the User Group.

For more information on this release, please contact: Christof Heisser President MAGMA Foundry Technologies, Inc. 10 N. Martingale Road, Suite 425 Schaumburg, IL 60173

Phone 847-969-1001 ext. 225 Email cheisser@magmasoft.com Web www.magmasoft.com

 Agency contact: Wendy McCormick Bernard & Company 847-934-4500 wendy@bernardandcompany.com

 

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Heidelberg Foundry Amstetten Simulates Casting Processes with MAGMASOFT®

Simulation in action: casting quality, realizing innovation, reducing costs

The 1400 °C hot cast iron melt gushes through the gate into the mold. The movement of the flowing metal in the casting rigging and in the gradually filling mold for printing press cylinders and the subsequent solidification process are only chaotic and accidental, at first glance. The engineers of Amstetten Foundry, which forms part of Heidelberger Druckmaschinen AG, are familiar with every detail of the casting system. They ran through the entire process in advance with simulation software. This enables them to predict precisely what the quality and characteristics of the cast iron cylinder will be, when it leaves the mold and is finally integrated in a Heidelberg printing press.

The Amstetten factory is one of the most up-to-date and efficient foundries in all of Europe. It acts as a center of excellence for the manufacture of castings, such as printing press side panels or cylinders, for the entire Heidelberg Group, which has a yearly revenue of three billion euros (~$4.4 billion) and 15,000 employees. The parts are core elements of the sheet-fed offset presses that Heidelberger Druckmaschinen AG, as the market leader, provides to users in the print media industry worldwide. “For our customers, just like for ourselves, the decision for Heidelberg is always a decision for quality,” is how Jürgen Schimmel, Director of Pattern & Casting Engineering describes the company’s vision, which he implements on a daily basis together with the 450 employees involved in casting production. This is because the quality of the individual presses to a significant degree depends on the quality of the castings produced in Amstetten.

Amstetten’s staff does not just produce castings for the Heidelberg Group: 50 external companies order large and small castings in differing batch sizes from the Amstetten foundry. Free market competition does not just make economic sense; it also serves to ensure that all processes are focused on achieving the highest quality, according to Schimmel.

“We have a clearly defined goal: economical casting production with consistently high quality. We see casting as part of an overarching process, beginning in design and finishing in reliably functioning, competitive end products,” Jürgen Schimmel says when formulating the “mission” of the Amstetten foundry. This level of quality is achieved by continuous IT support over the entire production process – from design of the components and patterns to the stable computer controlled melting and pouring processes.

Casting simulation bridges the gap between design and production

The planning department Pattern and Casting Engineering bridges the gap between computer-aided product design and actual production using MAGMASOFT®, the leading software for simulating casting processes. In doing so, the engineers rely on a technology regarded in the industry as one of the most important innovations of the last 50 years. This is because casting process simulation opens up the possibility of taking a look inside the former “black box” of the mold, to understand and predict precisely what happens during pouring and solidification of the melt. As a result, the foundrymen are in a position to accurately characterize the casting and production process as well as predict the casting’s properties before production has begun. What this means in practice is that the engineers are in a position to develop a casting with defined qualities at their computers. Correct production parameters for the casting process, with which the casting can be produced economically and reliably, can be developed with calculable quality. Before simulation technology became available, the individual development steps had to be taken “by hand” – from the part design to its realization as a casting by means of numerous, expensive test castings – and at the end there was still no guarantee that the process would indeed be reliable enough for the casting to be produced in the defined quality.

Save on costs, implement innovations

The foundry of Heidelberger Druckmaschinen AG makes use of simulation technology throughout the entire product and process development process, in order to save materials and costs in a highly price-sensitive market on the one hand, and to drive innovation and optimize component integration on the other.

For example, so-called return scrap is saved by “riserless” casting. Since the melt contracts when it cools, like any material, additional metal usually has to be introduced into the mold via the risers in order to avoid defects / porosity – so-called shrinkage cavities – in the casting. Appropriate design of the casting process reduces return scrap and material consumption. Before making the investment decision for MAGMASOFT®, the foundry had calculated that using simulation return scrap could be reduced by eight percent – which would lower annual material costs by a six-digit euro figure. Additional cost savings accrue from optimization over the entire process. Thanks to the calculated cooling times, it is safe to run production at the fastest possible rate.

For instance, it was possible to greatly reduce shrinkage cavities during the manufacture of a chain guide by reducing riser volumes and altering the gating system. This not only resulted in a significant quality improvement, but also led to a reduction of €15.80 (~$22.75) per part in manufacturing costs, primarily from a reduction of approximately 2.5 kg in return scrap. Given an annual production of approximately 300 pieces, this comes to cost savings of around €4,700 (~$6,768).

Thanks to solidification simulation, it was possible to reduce the number of risers from 5 to 2 together with a 69 kg reduction in return scrap during production of a gear wheel, which lowered manufacturing costs per piece by €31 (~$44.65).

Simulation pioneer as technological partner

As its technology partner for simulation, Heidelberg Foundry relies on a pioneer in this methodology in MAGMA Gießereitechnologie GmbH, Aachen. In the late 1980s, MAGMA transformed casting simulation from university research to practical application. Ever since, the resulting software solution, MAGMASOFT®,® has set technical standards when it comes to simulating casting processes. It simulates mold filling, solidification and cooling during the casting process as well as mechanical properties, residual stresses and distortion of the castings created.

MAGMASOFT® consists of a basis package and a series of additional modules which cover all casting process production steps. They support the user starting from the design of the component, the selection of the melt treatment and casting layout, through pattern design and mold production to final heat treatment and finishing. The MAGMASOFT® application spectrum covers all cast materials, such as gray and ductile cast iron as used at the Heidelberg Foundry as well as aluminum and steel. Every casting process can be simulated with the software in order to design and assess the casting and tooling layouts, cycle times and casting quality.

Simulation software selection criteria

“User-friendly operation, short preparation time until start of calculations, realistic representation of results – those were the leading functional criteria when we chose MAGMASOFT®,” explains Hans Frieß, Director of Planning/Material Management. “And of course, another factor was the potential for future developments in the software.” But it was not just the software’s functionality and quality that were relevant to the decision. MAGMA itself as simulation pioneer was a factor. Hans Frieß puts it like this: “MAGMA established casting process simulation technology as a practical tool. The industry owes its trust in simulation primarily to MAGMA. The associated market and technological leadership and references were also persuasive when we were thinking about introducing a solution.”

Amortization in one year

In the meantime, cooperation in Amstetten with MAGMASOFT® and MAGMA has a track record of about eight years. The investment was amortized within just one year instead of two, as calculated prior to acquisition. The use of the simulation solution has resulted in faster component development, higher component quality and more economic production. The technology has also assisted the foundry in terms of innovation: using MAGMASOFT made it possible to begin manufacturing larger, heavier types of components.

Simulation marketing

The software also plays an important role in marketing and sales. When potential customers inquire about a particular casting, they are not only provided with a price, but also a pledge of reliable component quality and delivery times, based on simulation results. “Thanks to our use of MAGMASOFT®, we have actually acquired customers. When we made the investment decision this effect was one we had neither expected nor taken into account,” Hans Frieß is pleased to note. MAGMA now occupies a correspondingly prominent place in marketing as well: there are numerous casting simulation visualizations on the foundry’s website, shown as recognizable screenshots from the MAGMA software.

Simulation communication

And something else has undergone further development on the basis of the simulation software: communication with the casting designers and the foundry floor. The designers quickly get reliable feedback on whether a new component design is “castable”, while production gets reliable information on how to handle the casting process to achieve the best result. Conversely, based on the documented simulation results, both parties with their expertise can prepare creative solutions, which in turn can then be quickly and easily checked using simulation.

Simulation in the future – knowledge management and service orientation

“Using casting process simulation has now become indispensable for foundries,” Hans Frieß sums up. This was the only way for them to become service providers, taking on design and consultative activities and cooperating more closely with the companies using castings. Moreover, the software protects against know-how loss, since the knowledge is no longer just in the head of an expert but instead stored in a way that can be reused in MAGMASOFT®‘s databases. Consequently, the partnership between foundry and software will intensify further in the time to come – and continue on the basis of a new software generation, which will be launched shortly.

Picture material:

Solidification simulation of a MAGMASOFT®-optimized casting for a Heidelberg printing press (here: gear wheel). Riser optimization produced savings of almost € 40,000 (~$57,600) on this single part.

 About software for casting process simulation

Casting process simulation software considers the complete casting process including mold filling, solidification and cooling, and also provides the quantitative prediction of mechanical properties, thermally induced casting stresses and the distortion of cast components. Simulation accurately describes a cast component’s quality upfront before production starts, thus the casting layout can be designed with respect to the required component properties. This results in a reduction in pre-production sampling, but also the precise layout of the complete casting system leads to energy, material and tooling savings for the foundry.

The range of application of MAGMA solutions comprises all cast alloys, from cast iron to aluminum sand casting, permanent mold and die casting up to large steel castings. The software supports the user in component design, the determination of melting practice and casting methodology through to mold making, heat treatment and finishing. This saves costs consequently along the entire casting manufacturing line.

During the last 10 years, the use of casting process simulation has become a valuable business asset for many foundries. MAGMA5 now expands the capabilities of casting process simulation and will further accelerate the acceptance of this technology.

About MAGMA

 

MAGMA offers comprehensive solutions to the metal casting industry, casting buyers and casting designers worldwide. The MAGMA product and service portfolio includes the powerful modular simulation software MAGMASOFT®,with the newest release MAGMA5, as well as engineering services for casting design and optimization.

Today, MAGMASOFT® is used throughout the metal casting industry, especially for the optimization of cast components in automotive and heavy industry applications.

MAGMA Giessereitechnologie GmbH was founded in 1988 and is headquartered in Aachen, Germany. A global presence and support are guaranteed by offices and subsidiaries in the USA, Singapore, Brazil, Korea, Turkey, India and China. Additionally, more than 30 qualified partners represent MAGMA around the world.

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 For more information on this release, please contact:

Christof Heisser

President

MAGMA Foundry Technologies, Inc.

10 N. Martingale Road, Suite 425

Schaumburg, IL 60173

Phone 847-969-1001 ext. 225

Email  cheisser@magmasoft.com

Web    www.magmasoft.com

Agency contact:

Tim Daro

Bernard & Company

847-934-4500

tdaro@bernardandcompany.com

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MAGMA: PREMIER ALUMINUM ANNOUNCES VIRTUAL TECHNOLOGY CENTER

Wisconsin foundry prospering from its use of technology, including MAGMASOFT® simulation software for metalcasting

Schaumburg, IL – Premier Aluminum is an ISO 9001-2008 certified permanent mold aluminum casting and machine shop in Racine, Wisconsin with a reputation for partnering with its customers to find flexible and cost-effective solutions for a variety of products.  The company serves the quantity casting market, from a few hundred castings per year to annual volumes of fifty thousand and more.  Premier positions its capability in the market as a one-stop shop for finished machined, permanent mold aluminum castings.

Premier has invested in all necessary tools and facilities to enable full collaborative engineering with its customers.  Its current goal is to achieve the desired casting quality by further reducing costs and decreasing time to market for its customers.  This progressive approach to working with customers by utilizing advanced technical tools in an R&D facility will now be referenced as the Technology Center at Premier Aluminum.

The Technology Center will now be available to any Premier customer or potential customer who wishes to work closely with the Premier Engineering Team to quickly and accurately develop new products or re-engineer already existing ones.  Its engineering team boasts 50+ years experience in metalcasting, plus the latest advancements in the aluminum foundry industry.  To better serve its customers, Premier employs such advanced software as Solidworks, MAGMASOFT® and other engineering tools to enhance customer confidence in tool life, product quality and efficient manufacturing processes, through a more predictive and trackable engineering protocol.

One of the company’s most effective engineering tools is MAGMASOFT®, provided by MAGMA Foundry Technologies, which is a software used to assist engineers, designers and buyers in the metalcasting industry.  Premier’s engineering group utilizes MAGMASOFT® to optimize the casting design as well as to refine the casting process from the outset.  MAGMASOFT® blends science, technology and experience from diverse areas of the casting process to create a package that utilizes the complex physics of casting to simulate the results prior to creating the mold.  This technology-based strategy, combined with years of experience serving the global foundry market, allows Premier to optimize its designs for castability, quality and overall lowest cost.

In today’s environment, Premier is seeking all possible ways to be competitive and work together to find solutions that ultimately benefit the entire supply chain.  Supply chain efficiency reduces time to market and engineering costs, emphasizes collaboration and yields sound manufacturing processes that will increase customer competitiveness.  The company is committed to this technology-driven approach and seeks the opportunity to share it with current customers and prospects alike.

Premier’s sales manager, Kevin Kelly, is currently inviting customers and prospects to send their product experts to the Technology Center for an opportunity to collaborate with the company’s engineers on any new products or existing designs.  During the visit, customer or prospect teams will be able to access the Internet, collaborate face-to-face with Premier’s engineering staff, gain knowledge of the aluminum casting processes and utilize any of the technology tools, especially MAGMASOFT®, to bring their product to market faster, more efficiently and at a lower overall cost.

For more information on this announcement, please contact:

Kevin Kelly – Sales Manager PREMIER ALUMINUM 3633 S. Memorial Dr. Racine, WI 53403 Phone: 262-554-2100, Ext. 130 Email:  kevin.kelly@premieraluminum.com Web:  www.premieraluminum.com

OR

Steve Sikorski – Vice President of Applications & Technology MAGMA Foundry Technologies, Inc.

10 N. Martingale Road, Suite 425 Schaumburg, IL 60173 Phone 847-969-1001, ext. 223

Email: ssikorski@magmasoft.com Web:www.magmasoft.com

Agency contact: Tim Daro Bernard & Company 847-934-4500 tdaro@bernardandcompany.com

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