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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


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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MAGMA presents the economic benefits of casting process simulation at GIFA 2011

The process orientation of MAGMA5 illustrated using die casting

During the upcoming GIFA 2011 show in Dusseldorf, Germany, Magma will present its new software generation for casting process simulation, MAGMA5. At the 300 sq. m stand 12A16, the company will demonstrate how casting process simulation with MAGMA5 can be used for optimization at all stages of casting manufacturing to contribute to foundry profitability. MAGMA will show the newest version MAGMA5 5.2 with extended capabilities for all cast materials and processes, introduce its new software MAGMA C+M for the simulation of the core production processes and provide a view into the future of autonomous optimization of casting processes. Additionally, MAGMA is participating in the initiative “ecoMetals” from the Messe Düsseldorf, which supports companies who develop innovative products and processes leading to a more efficient use of energy. MAGMA will demonstrate, using practical examples, how the application of casting process simulation considerably increases a foundry’s energy and resource efficiency.

MAGMA5 – optimized simulation

Autonomous optimization of casting processes and layouts, shown here for gating optimization in die casting, is the future of casting processsimulation.

MAGMA5 5.2 introduces several new simulation capabilities: new process modes for permanent mold, low pressure sand and low pressure die casting, as well both hot-chamber and cold-chamber die casting, allow for detailed process-specific definitions. The software also supports process design by controlling process parameters during a simulation run. For gravity casters, process modules for DISAMATIC and investment casting are now available.

At GIFA, MAGMA will also present its newest developments for the quantitative prediction of as-cast and heat treated local microstructures and properties in aluminum, iron and steel castings. MAGMA5 simulates sand and reoxidation inclusions during mold filling and predicts defects related to molding materials. MAGMAnonferrous calculates the final microstructure and mechanical properties for aluminum alloys considering the metallurgy, inoculation, and hydrogen content of the melt. MAGMAiron predicts local microstructures for iron materials from graphite growth through to the distribution of phases making up the matrix. MAGMAsteel calculates macrosegregation in steel castings and the local microstructure resulting from heat treatment.

The stress module MAGMAstress for the first time offers casters the option to calculate thermally induced casting stresses in permanent molds for all manufacturing steps, including heat treatment and finishing, in order to predict casting crack problems and distortion. The simulated distortion results can be evaluated just as on a coordinate measuring machine and compared directly with real measurements. For the first time, the new module MAGMAdielife facilitates the evaluation of the effects of tooling design and thermal stresses on the durability of permanent molds.

MAGMA Core+Mold – transparency in core production

With MAGMA C+M, the simulation of the core shooting process is possible for complex tools, shown here for three cores including blow tubes in a single core box.

With MAGMA C+M, MAGMA introduces an integrated tool for the simulation of core production processes. MAGMA C+M simulates core shooting, blowing and hardening of organic and inorganic cores. Processes where binder hardening is driven by a catalyst gas as well

as core production with tempered core boxes are supported. MAGMA C+M considers all aspects of core production starting from the core shooter, in order to calculate the flow of the air-sand mixture based on the real shot parameters. An integrated database provides the ability to specify the characteristics of the sand and the binder system as well as core box vents and blow tubes. The program simulates gassing, purging and the curing reaction of gas-hardened cores. The design and control of core box tempering for heat-cured cores (hotbox, croning, inorganic) is effectively supported by modeling of heating cartridges and oil channels.  For inorganic cores, MAGMA C+M calculates the drying of the core in the heated core box as well as due to transport of water vapor by hot air during gassing. MAGMA C+M takes advantage of all the functionality of MAGMA5 and is available as an add-on module to MAGMA5 or asa stand-alone product.

Autonomous optimization is the future

With autonomous optimization, foundrymen can make use of simulation in order to pursue their objectives for quality and cost. Autonomous optimization makes proposals for the right casting layout or the optimum process parameters. The virtual test foundry in the computer enables variation of parameters and systematic examination of influencing variables leading up to the optimum configuration. Based on the fundamental physics embedded in MAGMA5, the program finds the best possible dimensions and positions of ingates, as well as the location of feeders and chills including their optimum size. Using industrial examples, MAGMA will present state-of-the-art capabilities and provide a view into the future of optimization.

MAGMA – very involved

At the accompanying WFO Technical Forum, MAGMA will give presentations on the topics of aluminum casting, core production, and optimization. At the NewCast exhibition, which takes place in parallel with GIFA, simulation specialists will discuss the prediction of residual stresses and distortion in cast iron components.

MAGMA also has a further exhibition stand (12A15) as part of the “Get-In-Form” project “Youth-Technology-Future” (“Jugend-Technik-Zukunft“).  Here, the attractiveness of work as a professional or specialist in the metal casting industry will be illustrated to students and apprentices in an entertaining and interactive manner.

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.


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

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