Advances in CGI, Alloys

Jan. 24, 2008
Thresher Introduces High-Ductility Aluminum Alloy Thresher Industries reports it developed a new, high-ductility aluminum alloy it will promote for automotive components manufacturing, using its proprietary Direct Metal Induction Cast Process. ...

Thresher Introduces High-Ductility Aluminum Alloy

Thresher Industries reports it developed a new, high-ductility aluminum alloy it will promote for automotive components manufacturing, using its proprietary Direct Metal Induction Cast Process.

“Everyone at Thresher is extremely pleased with this development,” stated president and CEO Tom Flessner. “This alloy could revolutionize automotive structural engineering as we know it today, and will allow Thresher to move to the forefront in this automotive engineering field as well as finding other automotive applications.”

Hanford, CA-based Thresher Industries produces cast aluminum products and reinforced metal-matrix composite aluminum components.

Thresher’s Foundry Group has been working with its Talon Composites division to develop the new alloy, for which testing was completed only recently. The organization says it can supply the alloy to automotive parts manufacturers, which will lower the cost of production for customers and deliver new solutions to standard problems.

Flessner indicated the new alloy will be applicable to several of the group’s customers, including MGM Brakes, Alto Transmission and Baer Brakes, and potential future clients. “Not only will automotive engineers and designers benefit,” said Flessner, “but also the end consumer with the production of lighter, safer, and less expensive automobiles that will delivery better fuel economy.”

Thresher stated the alloy will lead to “reduction of overall vehicle weight and end costs, and when used with Thresher’s Nautilus Core technology it will allow engineers tremendous freedom of design.”

Also, Thresher reports it is studying locations in Michigan for a new plant that would begin operation by mid-2008. The new location would be a complement its 28,000-ft2 plant in Hanford, CA, as a way to serve its expanding customer base in the eastern U.S.

According to Flessner, “This new facility is a giant stepping stone in the development of Thresher Industries as an industry leader. We will be able to contact and attract new customers throughout the country, and cut time and shipping costs to our existing clients. Having this additional facility up and operational will allow us to continue on our path of growth and success. I look forward to announcing further details on this project in the near future.”

Excerpted from FM&T June 2007 issue, pg. 6

Ashland, SinterCast, International Casting to Offer CGI Packages

Ashland Casting Solutions, International Casting Corp., and SinterCast AB, formed a venture to offer “complete solutions” for CGI (compacted graphite iron) product design, development, and prototype production.”

ACS, a division of Ashland Performance Materials, supplies core and mold binder systems, refractory coatings, release agents, riser sleeves, metal cleaners, sand additives, and other specialty services. Sintercast supplies process control technology for highvolume compacted graphite iron production, and produces various CGI components ranging from 8 kg to 17 metric tons. It has CGI production agreements with 32 foundries in 14 countries.

International Casting Corp. is a New Baltimore, MI, foundry that produces a range of gray and ductile iron, and carbon and alloy steel castings for automotive, aerospace, and other industrial customers.

In a statement, ACS, a division of Ashland Specialty Chemicals, announced that the “combined capabilities of Ashland Casting Solutions, ICC, and SinterCast will provide concept-to-production support for new CGI components, including optimization of core blowing, mold filling, and solidification, component design for series production, prototyping and machining.”

The agreement further calls for ICC to install a SinterCast Mini-System 2000 to produce CGI prototype castings under series production conditions. ICC’s melting and casting facilities will be capable of producing CGI components from 1 to 750 lb.

“Building upon our successful marketing and technical alliance established with SinterCast in 2005, this expansion to encompass CGI design services, product development and prototyping skills, pulls together the components necessary to meet the current and future needs of the global automotive industry,” stated Scott Hoertz, v.p., Ashland Performance Materials and general manager, Ashland Casting Solutions. “With the combined expertise and innovation of Ashland, ICC and SinterCast, we are confident that we will be able to optimize CGI product designs and provide our customers with an efficient transition from CGI conception to series production.”

Doug Smith, president of International Casting Corp., said the “continuous increase in CGI development and production planning provides an excellent opportunity for ICC to apply its ferrous metallurgy product development and niche-volume production skills to the CGI arena.”

Sintercast AB president and CEO Steve Dawson said the agreement “significantly broadens SinterCast’s ability to promote new CGI product development activities and to support the subsequent CGI series production needs of the world automotive industry.”

Excerpted from FM&T Oct. 2007, p. 4