www.strikowestofen.com
June 2015
¤ 264,000
$ 290,000
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Innovations 2015
W
Pr
Re
Make Your
World
a Better
Place
Pr
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M
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2
Introduction
Numerous
Innovations
for
Sustainable
Business
As in the past, you can rely on us if you’re looking for technology to make the
casting process more sustainable. Sustainability is not just a slogan for us.
When developing new options and products, we give equal priority to economic
efficiency, ecology and the human being. Those who work with our products are
the most important people we talk to when we develop new products. This is
why we provide solutions which give our customers more profits, consume less
energy and resources, minimize emissions, make the production process safer
and easier to control and create a clean and pleasant environment to work in.
And we provide them in the same quality everywhere in the world.
StrikoWestofen
Efficiency. Powered by knowledge.
www.strikowestofen.com
3
Hot gas baffle
Quick connect coupling for pipes
PLCDos control
Westomat ® Plus+
StrikoMelter ® BigStruc ®
P. 16
Biscuit correction
Melt concepts
Stirrer
Optional dosing accuracy ±1%
Webserver 4.0
Schnorkle®
Gas-fired crucible furnace
P. 36
Metal yield
Low metal loss
StrikoMelter ® PurEfficiency ®
Near-stoichiometric burner setting
Casting
Energy recovery
StrikoMelter®
Operation and fault message concept
Crucible furnaces
P. 58
ProDos Diagnostics 8.63
PneuCo®
Lofometer
Self-sealing lift swing doors
Worldwide
P. 66
P. 40
4
FOREWORD
StrikoWestofen is a
company, a brand and
a synonym for state-ofthe-art technology in
the light metal casting
industry.
The year 2015 is already proving to be a particularly exciting one. The demand for cast
light metal parts continues to grow, and so do the requirements which production technology has to meet. And again, it is the GIFA which provides a special forum every four
years allowing the further development of the available technology to be experienced.
For us, too, this is a perfect opportunity to show what new things we can contribute.
We’re presenting nearly two dozen innovations this time. Why not talk to us and find out
what new things we’ve got in store for you?
Yours, Rudi Riedel
[email protected]
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A GAIN FOR COMPANY AND ENVIRONMENT
Production
line
En
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IS
NE
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Do
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Up
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f fi
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5
6
THE FACTS
Some statistics
tell stories and can
change the world
KNOWLEDGE
POWER
EFFICIENCY
We have not only resolved to offer the best technology available - we
also keep our pledges. With our products, we would like to allow
casters to make measurable savings on metal and energy consumption and minimize rejects in production. This is why we don’t
communicate performance parameters determined in the laboratory;
instead, we use the ones measured and confirmed by our customers
in everyday foundry operation. Take us at our word and ask for concrete covenants. An example? Plus 2: a StrikoMelter PurEfficiency can
help you to increase your annual profits by 2 percent points. By using
a StrikoMelter Purefficiency, a foundry company producing 5,000 t of
cast aluminium parts annually can save at least € 66,000 on energy
and € 198,000 on metal loss compared with any other furnace technology available on the market. This means € 264,000 more profits
per year, i.e. a direct improvement of profits by 2 percentage points.
Please see the following pages to find out which performance parameters this is based on and for further concrete statistics.
M
EA
SU
RA
BL
E
FA
CT
S
e. g.
We keep our promises: we have a tradition of thrift with regard to energy consumption. It was 4 years ago
that we first presented the new StrikoMelter PurEfficiency with its energy consumption of only 525 kWh/t of
aluminium, and now we can provide values measured using many delivered examples of this unique furnace
technology. With it, we achieved consumption values of as little as 489 kWh/t for melting and holding.
489 kWh/t
e. g.
The greatest cost driver in the manufacture of molten metal continues to be the metal loss occurring during
melting. As before, the StrikoMelter achieves a metal yield of up to 99.75 % – not just on paper, but under
real-life conditions in the foundry. We will gladly calculate for you what you can get out of your raw material
using the StrikoMelter - no matter whether it’s ingots, returns, rejects or chips of all sizes and thicknesses
we’re talking about.
99.7 %
e. g.
Now, for the first time, a dosing furnace can achieve a dosing accuracy of ±1 %. New algorithms
in the software of the new ProDos 3 control increase the dosing accuracy of the Westomat to ±1 %.
±1 %
e. g.
Even just the StrikoMelters delivered in the year 2014 worldwide have a total melting performance of 1,113,000 t of aluminium per year. We are aware of the responsibility posed by the
energy consumption which this figure implies. That is why we work every day on reducing it still
further. The outcome: the StrikoMelter shaft melting furnaces installed in the year 2014 save an
annual total of 44,520 t of CO2 emissions compared with the other melting furnace technology
available on the market. This protects the environment from greenhouse gases corresponding
with the CO2 emissions of a fleet of 23,400 vehicles.
44,520 t CO2
16
The new Westomat Plus+ newly
designed. Makes your world better.
Chapter A
StrikoWestofen
17
INNOVAT IONS
Westomat Plus+
®
And Westomat
Extremely easy
setup
fit
t ro
Re
en
ov
· Biscuit correction
· PneuCo for the flanged riser tube
· ProDos Diagnostics 8.63
· Low metal loss of Westomat
· Upgrade of ProDos 3 control
· Upgrade of biscuit correction
· Flanged riser tube
· PneuCo for the flanged riser tube
· Rim cleaning jet
· SMS fault message module
· Cast-iron filling funnel with
remote control
· Refractory interchange part
· Refractory relining, optional rental
furnace body, or furnace
The Westomat is a clean, closed system which is now child’s play to set up
and operate. Its availability is unequalled, and so is its productivity. Nevertheless, the cleaning and maintenance effort required is extremely low.
As a measure of the uniqueness of the Westomat, we are almost proud to see how often it has been copied in the
meantime but never equalled. One area in which the Westomat is quite definitely unequalled is its service life. Our
customers are now still using systems which went into operation 25 years ago. The Westomat can be integrated
into any pressure die-casting system, but into gravity casting systems too. With versions displaying a capacity of
from 450 kg to 3,100 kg, the Westomat covers all sizes of cast parts.
We have now sold a total of almost 5000 Westomats all over the world. This means we know the experiences and
needs of our customers in a wide range of applications. We have included these requirements in the development
of a new Westomat: the Westomat Plus+.
Chapter A
· Westomat Plus+
· Option dosing accuracy ±1 %
·P
LCDos – controls for all casting methods
· Webserver 4.0
· Operation and malfunction notice concept
· Lofometer – Contact-free flow measurement for molten metal
Pr
NE
W
®
18
Chapter A
Westomat
Plus+
StrikoWestofen
®
I
E: S T R
OR T.
M MA
A D TO
RE E S
W
5000 Westomats sold mean 5000 examples of the experience our customers have collected with the units, and these examples were valuable and inspiring for our product
development. We turned everything upside down for the new Westomat Plus+, including
handling, measuring technology, the controls, dosing accuracy, space requirements,
heating, pneumatics and, last but not least, operating safety.
We think the result is quite an achievement for pressure die-casting, and for the casting
of structural components in particular. It’s quite an advance for gravity die-casting too.
KO
W
ES
TO
FE
M
CO
N.
The new Westomat Plus+ is notable for its extraordinary design. It is the work of the internationally famed machine designer Mr. Jürgen R. Schmidt and his Design Tech team.
We wanted to also provide light metal foundries with the things that are already common sense on machine tools used in tool shops and parts manufacture: machines and
equipment which give customers and employees alike a modern, dynamic and efficient
production environment - and create an enjoyable environment in which to work.
HERE ARE A FEW HIGHLIGHTS:
+ Modern new compact design with greatly
reduced space requirements
· Now a Westomat Plus+ 1200 S fits into the
footprint of a Westomat 900 SL
+ Overhead heating instead of heating rods
· Simple replacement from above without
requiring space at the sides
· Up to 3 times longer service life
· No transformer necessary
· Greatly reduced risk of damage during
cleaning
· No leaks in the junction boxes/heating
block stones
· No corundum formation
+ Delivery with ready-installed lift table
(up to size 1700)
· T ime-saving installation (plug & play)
· Less space required during transport
+ Lift table can be tilted in any position (by
installing two cylinders: a lifting and a
tilting cylinder)
·C
an be cleaned and emptied in any position
+ Lift table optionally fully covered
(closed design)
·M
eets even maximum safety requirements
in foundries
· Reduces risk of squashing
· Completes the new design
+ New pneumatic unit
· Even higher process reliability
· Even easier to maintain
Westomat Plus+, Westomat
www.strikowestofen.com
Everything is put to the
test: the new Westomat
Plus+ sets standards, not
only in design.
19
R
W E AD
ES M
TO O
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This statement by an automotive customer is not an isolated case. The key data
show the efficiency, precision and reliability of the Westomat Plus+. The investment gives your production a competitive edge.
“Design and concept of the new Westomat Plus+ were so convincing that we ordered
the second Westomat Plus+ before we’d even tested the first newly delivered one.“
20
Chapter A
StrikoWestofen
www.strikowestofen.com
21
GUMMERSBACH . GERM AN Y
Westomat Plus+, Westomat
A22
THE PRODUCT
Option dosing accuracy
±1 %
OPTIONS
New
Proven
Retrofit
THE ADVANTAGES AT A GLANCE

Dosing accuracy of up to ±1 % possible

Improved compensation of

Simplified and reproducible setting of
Within the ProDos 3 control, the algorithms of a newly developed software
allow the virtually exact determination of the dosing weight with the help of
the feed pressure curve. This increases the dosing precision of the Westomat
to ±1 % and improves the compensation of pressure fluctuations as well as the
reproducibility when different correction factors are set.
pressure fluctuations
different correction factors
Dosing control ProDos 3 with optional dosing accuracy of ±1 %
A23
THE PRODUCT
PLCDos control for all
casting methods
OPTIONS
The PLCDos control is a development based on the integrated TIA Portal
Engineering Framework (SIEMENS). As an alternative to the ProDos 3 control, it
is particularly suitable for implementing special functions in pressure die-casting and gravity die-casting. The PLCDos control provides a straightforward
operation and malfunction notice concept and allows the easy implementation
of customer-specific requirements while maintaining a high safety standard
thanks to protected basic functions for dosing operation. All proven and up-todate innovations associated with the ProDos 3 control are also available in the
PLCDos control.
New
Proven
Retrofit
THE ADVANTAGES AT A GLANCE

Many special functions possible

Straightforward operation and malfunction

High safety standard
notice concept
· Protected basic functions for dosing
operation

Includes innovative features of the
ProDos 3 control
· Integrated web server
· External access to data possible
· Analysis of all relevant system parameters
in seconds
Visualization of the new PLCDos-control
A24
THE PRODUCT
Option web server 4.0
OPTIONS
New
Proven
Retrofit
THE ADVANTAGES AT A GLANCE

Rapid download of all process data from the

Integration of the ProDos 3 control into the

Remote diagnostics possible via ProDos

High safety standard

Integration of the process data into the
last 350 cycles
internal company network
Diagnostics
internal company control system after
transmission
The web server for the ProDos 3 control allows you to integrate it into your
local company network. This enables you to call up all relevant information
easily from your office desk. For example, the pressure in the furnace chamber
or the temperature and weight of the molten material can be kept under observation. Error messages are transmitted too, and all process data from the last
350 cycles can be downloaded. All process data transmitted can be processed
further by a company control system. In addition, simple service functions can
be used via the diagnostics tool ProDos Diagnostics or by remote diagnostics.
The high safety standard of this system guarantees that no-one can intervene
into the process from the outside.
EFFICIENCY
at a
glance
With the web server 4.0 informed at any time about current and past process data – including remote
diagnostics, comfortable from your office desk.
A26
THE PRODUCT
Operation and
malfunction notice concept
OPTIONS
New
OPERATION CONCEPT
Proven
Retrofit
The ProDos 3 control includes all functions and operating modes required in
die-casting, including the necessary software tools and assistance for
the operator.
THE ADVANTAGES AT A GLANCE

Easy, intuitive operating concept

Control of all functions and operating modes

Quick input of production parameters

Setup assistant for first startup

Dosing weights can be determined without

Fault reporting, analysis and documentation
reference weight
A new operation concept was developed to make operation even more simple and straightforward. Besides an initial overview image for the operator,
the intuitive user interface provides two further levels only – one for the
basic settings of the Westomat and one for all maintenance functions. This
allows the user to find the required functions quickly and easily. All requirements of pressure die-casting can be parameterized individually and within
a short time according to the demands.
The initial commissioning of the Westomat can now also be carried out by
foundry personnel with little experience. A set-up assistant executes all
necessary steps in the specified sequence. It is now no longer necessary to
weigh a number of reference weights in order to coordinate the dosing quantity. The dosing weight can now also be entered directly and recalibrated
easily when required.
MALFUNCTION NOTICE CONCEPT
The new malfunction notice concept provides a complete overview of the
occurrence and elimination of all current and past errors. Thus, the controls
documents not only every change, but also any errors which the system has
eliminated by itself. In addition, the specialist personnel have access to several histograms which can be called up at any time and contain comprehensive
information on the state of the heating system, the control and the dosing
system, allowing them to react in a more rapid and targeted way when service
is necessary. This feature is completed by the “integrated web server” option,
which provides a rapid overview of all relevant functions of the Westomat from
your office desk.
HELP CONCEPT
The help concept provides a simplified and precise help text in the national
language for each preselectable item on the operation menu. The use of icons
with a high recognition value also improves the multilingual design of the
control – an advantage for training courses or for personnel speaking different
languages too.
A27
THE PRODUCT
Lofometer – contact-free flow
measurement for molten metal
OPTIONS
In order to advance process reliability in the pressure die-casting process even
more, it is necessary to also analyse parameters which cannot be captured by
measuring instruments as yet. In cooperation with the Technical University of
Ilmenau, we have now developed a completely new measuring instrument. As
there was no suitable instrument for measuring the flow rate of hot metal melts
up to now, the contact-free flow meter “Lofometer” was developed for metal
melts on the basis of the physical effect of the Lorentz force as part of a ZIM
project (www.zim-bmwi.de). This allows production downtimes and reject rates to
be reduced still further.
By measuring the quantity of melt actually dosed at the exit of the riser tube, it is
now also possible to capture factors with a negative influence as well as sudden
fluctuations, for example those occurring due to wear, breakage, deposits or
fluctuations of the measuring technology with regard to various components
of the dosing furnace or during filling. Examples of causes for incorrect dosing
are cracks in the riser tube, contaminations of the melt, deposits on the pouring
rim or scanning electrode and changes to the riser tube nozzle from breakage or
washing out.
The Lofometer allows these changes in the dosing behaviour to be reliably
detected and compensated or eliminated. Even today, the flow meter has a
measuring precision reaching down to ±1 %.
New
Proven
Retrofit
THE ADVANTAGES AT A GLANCE

Measures the actual dosing

Changes in the dosing behaviour are relia-

Biscuit fluctuations can be

Measuring accuracy: ±1 to ±1.5 %

Can also be retrofitted to existing
quantity dispensed
bly detected and compensated or eliminated
compensated easily
Westomat systems
With the development of the Lofometer, we are adapting to the continuing
increase in the quality and efficiency requirements in aluminium pressure
die-casting. This provides foundries with an extremely useful tool allowing them
to advance the error-free operation of their casting processes still further. The
measuring instrument can also be used with other metals and electrically conductive fluids. We are looking forward to a lively exchange of views about your
requirements with regard to increasing productivity and reducing reject rates.
Westomat in StrikoWestofen’s pilot plant, with
Lofometer attached to the riser tube
A28
THE PRODUCT
Biscuit correction
OPTIONS
New
Proven
Retrofit
THE ADVANTAGES AT A GLANCE

The drifting of the dosing weight is com-

Incorrect settings on the part of the opera-
The biscuit correction system has proved its worth many times over, and more
than 150 of them have been sold and used in the corresponding number of
foundries by now. It makes a significant contribution to increasing the process
reliability by effectively compensating the drifting of the dosing weight and
thus helping to prevent incorrect settings on the part of the operator. The new
and improved version of the biscuit correction is now fully integrated into the
ProDos 3 control, so that an extra PLC is no longer necessary.
pensated
tor are prevented
· High process reliability

Now integrated into the ProDos 3 control

Reduction of the “out of tolerance” rate by
· No additional PLC necessary
up to 2 percentage points
· Reduction down to 1 % within a tolerance
range of ±1.5 % of the dosing weight
Dosing curve over 350 dosing cycles in a tolerance range of ±1.5 % of the dosing weight. Out of
tolerance rate within a range of <1% (proven).
A29
THE PRODUCT
PneuCo® for the flanged riser tube
OPTIONS
The PneuCo system is the contact-free alternative to top stop measurement
using a scanning electrode. The pneumatic control of the PneuCo system uses
pressure change to measure the increase of the molten metal in the riser tube
up to the desired level. A small air-volume flow is directed from the output of
the pneumatic control to the place where scanning takes place (small hole) in
the dosing pipe. As soon as the rising level of molten metal closes the air outlet in the dosing pipe, the pressure in the PneuCo system escalates. This rise is
detected by a pressure switch and passed on to the dosing control as a dosing
contact. The switching process carried out in this pressure switch corresponds
with that of the dosing contact used in classical electrode scanning.
New
Proven
THE ADVANTAGES AT A GLANCE

Contact-free top stop measurement works
permanently without wear, i.e. without
affecting the dosing accuracy

The PneuCo system is now also available

If both systems are used, PneuCo
for the flanged riser tube
allows error-free adjustment of the
scanning electrode
Flanged riser tube with PneuCo system
Retrofit
A30
THE PRODUCT
ProDos Diagnostics 8.63
OPTIONS
New
Proven
Retrofit
THE ADVANTAGES AT A GLANCE

Stability of the production process under
scrutiny at all times
· Analysis of the dosing precision using the
biscuit thickness
· Display of the dosing weight curve while
including all possible operating conditions
· Support in the adjustment of individual correction factors (refill correction, after-effect
correction)

Error detection when there are interface
problems
· Recording of all interface signals between
Westomat and casting system
The new version of the diagnostics software ProDos Diagnostics offers a
wealth of new options in comparison with the predecessor version 8.61. The
comprehensive analysis of the dosing precision using the biscuit, the display
of the dosing weight curve under inclusion of all possible operating conditions as well as targeted assistance in the adjustment of individual correction
factors allow the user to assess the stability of the production process at a
glance. If there are interface problems, it provides a simple error detection
system. This includes the recording of all interface signals occurring between
casting system and Westomat, an impulse diagram of the last dosing process
and an impulse diagram of the last interface error.
To be able to make full use of all functions of the software, it is a good idea to
use it in connection with our “web server” option. This allows you to download
all process data of the Westomat under examination from your office desk
within seconds and analyse it with a few clicks of the mouse. It also allows you
to detect sources of error in a rapid and targeted way.
The new ProDos Diagnostics 8.63 software is available to our customers
cost-neutrally and can be executed on the Westomat website (www.westomat.
com). It runs on all Windows systems from XP onwards.
· Impulse diagram of the last dosing process
· Impulse diagram of the last interface error

Analysis und error elimination are possible

Can be used via the Westomat website

Software available free of charge from
via the web server
(www.westomat.com)
StrikoWestofen
Diagnosis online under www.westomat.com
A31
THE PRODUCT
Low metal loss of Westomat
OPTIONS
Westomat dosing furnace or conventional ladle system? This is one of the
questions raised in connection with the modernization or expansion of casting lines. Especially the aluminium foundry industry with its high costs for
energy and materials must constantly ensure optimum operating states of its
systems. Excessive energy consumption, machine downtimes, material losses
due to contaminated melts, increased cleaning requirements or elevated reject
rates reduce the profitability significantly.
Westomat dosing furnaces are remarkable in particular for their process
reliability, the extremely low cleaning requirements and the quality of the melt.
Their closed system minimizes temperature fluctuations, water absorption in
the melt and oxide formation.
In particular metal loss, energy consumption and a low reject rate have a great
effect on the unit costs: using the Westomat reduces the metal loss by about
80 percent in comparison with a holding furnace with a ladle system, and the
energy consumption is reduced by more than 60 percent. Current empirical
surveys of practical use show that 15 to 20 additional castings within one 24hour shift are not unusual. Extrapolated over one year, this corresponds with
an increase in productivity of around 1.5 percent. Also, as a by-effect, a significant contribution is made towards improving the ecological footprint.
New
Proven
Retrofit
THE ADVANTAGES AT A GLANCE

Closed system

Low metal loss of only 0.06 %

Low hydrogen absorption

Increase in productivity of +1.5 %

Reduction of energy consumption by 2/3
A32
For Retrofit
performance increase and modernization of Westomat:
Upgrade to ProDos® 3
control
· Upgrade to ProDos 3 control
· Upgrade to biscuit correction
· Flanged riser tube
· PneuCo for the flanged riser pipe
· SMS error messaging module
· Rim cleaning jet for riser tube
THE ADVANTAGES AT A GLANCE
· Gray iron funnel with remote control
· Pre-fabricated refractory interchange part
· R
efractory relining, optional replacement of furnace
body or leased furnace
Our retrofit kit allows you to upgrade all older control generations to the new ProDos 3 control.
Improvement of the dosing characteristics using the new
option ±1 %
Optimum process reliability, high resistance against electromagnetic disturbances
Capacitive touch screen (no longer needs to be calibrated)
Error analysis and process optimization using remote diagnostics tool
Optimized process visualization as well as operating messages and error messages
Upgrade to
biscuit correction
THE ADVANTAGES AT A GLANCE
Minimization of the ‘out of tolerance’ rate, thus reducing
the reject rate
Constant communication with the die-casting machine
and automatic optimization of the dosing quantities in the
production process
Expanded functionality and dosing accuracy using integration of biscuit correction or DISPO 035 interface
Expanded transfer of dosing data and measured values to
the die-casting machine
A33
Flanged riser tube
Flanged riser tube with
PneuCo®
THE ADVANTAGES AT A GLANCE
ADVANTAGES IN ADDITION TO THOSE OF THE FLANGED RISER TUBE
A sealed flange to the furnace body guarantees the precise
fit of the riser tube, and its con-stant identical positioning
in the melt is guaranteed without requiring a new set-up
process. Installation errors are ruled out
Even lower dosing rates outside of the tolerance range
Reduction of the dosing rates outside of the
tolerance range
Rapid replacement and reduction of system downtimes
Elimination of all mechanical (i.e. wearing) parts for the
dosing contact
Rapid replacement of the wear part and reduction of
system downtimes
As refractory materials are no longer used, leaks caused by
shrinking refractory material can-not occur
The melt cannot be contaminated by hydrogen
One-size steel components and seals can be used for
different sizes of riser tube, so the quan-tity of spare parts
held in store is reduced considerably
SMS error messaging
module
THE ADVANTAGES AT A GLANCE
Automatic forwarding of operating messages and error
messages to mobile end devices
Improvement of the operating and process reliability in
unmanned operation at night or at weekends
A34
Rim cleaning jet for
riser tube
Gray iron funnel with
remote control
THE ADVANTAGES AT A GLANCE
THE ADVANTAGES AT A GLANCE
A targeted pulse of compressed air removes and
prevents deposits on the rim of the riser tube
Optimized shape for maximum flow rates and more
rapid filling
Reduction of the dosing rates outside of the
tolerance range
Optional remote control for the automatic opening of
the lid of the filling funnel
Reduction of the effort required for cleaning the pouring
rim of the riser tube
Cleaning process simpler and faster compared to
lined funnels
Improvement of process reliability and operating safety
Reduced absorption of atmospheric oxygen
As a refractory lining is not necessary, the contamination of
the melt with refractory particles is prevented
A35
Pre-fabricated refractory
interchange-part
Refractory relining, optional replacement furnace
body or leased furnace
THE ADVANTAGES AT A GLANCE
THE ADVANTAGES AT A GLANCE
Relining in 5 days: the pre-fabricated refractory interchange
part allows the system down-time to be shortened by up to
70 % if relining is required
Further options for guaranteeing the replacement of the
refractory lining (which becomes necessary at some point)
smoothly and without long downtimes:
The relining concept can be carried out on site in the
foundry
Furnace relining at the StrikoWestofen factory
Ensures the complete drying out of the refractory material
Reduction of the energy consumption in comparison with
current relining concepts by means of improved insulation
Extremely short heating up process after completion of the
work as the refractory inter-change part is delivered in the
pre-sintered state
Flushing batches not necessary for initial commissioning
Makes costly and time-consuming operation with flushing
batches unnecessary
Includes painting of the furnace body and subsequent
pressure test
A complete replacement furnace body allows even more
rapid replacement on site as only installation work is now
left to do.
36
Temperature-stable and safe:
The Schnorkle guarantees a
smooth melt transfer.
Chapter B
StrikoWestofen
37
INNOVAT IONS
Schnorkle
Safe transport
and transfer
The Schnorkle is a closed transport system with which
melt can be safely transferred from the melting aggregate
to the dosing or holding furnace of the die-casting system
in a closed container.
A semi-cover directly on the melting furnace is opened and the melt is introduced, either from the tapping valve of a fixed shaft melting furnace or by hydraulic tilting from a
tilting furnace. After the optional treatment of the melt and the closing of the semi-cover, the Schnorkle is transported to the die-casting system using a lift truck. By applying
pressure to the transfer ladle, which is hermetically sealed, the melt is fed directly into
the filling funnel of the Westomat. This guarantees the balanced, laminar filling of the
dosing furnace with aluminium and minimal contact between melt and atmosphere,
thus ensuring a reproducible filling process.
Thanks to this new system, it is no longer necessary to tip casting ladles at a great
height using a lift truck. In this way, a potential source of danger is eliminated and occupational safety is increased considerably. The design of the system enables the melt
to be treated with impellers and transported into the dosing system without having to
transfer it to another container.
Chapter B
®
B38
The advantages at a
glance:
Safe, simple operating principle
Process for supplying casting systems with molten metal is hermetically sealed
throughout, thus ensuring the safety of personnel and production system
Low-error pneumatic control for feeding the melt into the dosing or holding furnace
Compressed air supply either to the Westomat’s compressed air system using a quick
connect coupling or via a compressor permanently installed at the lift truck.
Constant flow rate at all times (after one-off basic pre-setting), thus keeping the filling
funnel in an optimally filled condition during refilling.
Very high safety for operator
and equipment
The closed container of the Schnorkle only has to be lifted slightly in order to reach the
filling funnel
No moving mechanical parts
Closed transport ladle – no open transport of molten aluminium
Increased metal quality through minimal contact of the molten metal with the atmosphere
No temperature fluctuations and no reduction of the energy consumption thanks to
closed system
More Advantages
Melt treatment using an impeller is directly possible in the Schnorkle
Increased degree of automation
Allows the Westomat to be used in low buildings too
Can also be used for the safe transport of molten aluminium within the foundry in a
closed ladle and for filling other aggregates and holding furnaces
40
StrikoMelter PurEfficiency
has fans all over the world
and they know why.
Chapter C
StrikoWestofen
41
INNOVAT IONS
StrikoMelter
New demands,
new versions
fit
t ro
Re
en
ov
· StrikoMelter PurEfficiency
· Metal preservation with the
StrikoMelter
· Automated and specific melting
solutions
· Hot gas baffle
· Triple bath filling monitoring
· Automatic shaft cover/
hot gas baffle
· Automatic tapping valve
· SMS fault message module
· Refractory re-lining
· O verhaul and exchange of
charging units
· Update and exchange of
control cabinet
· O verhaul steel construction and
burner system
· For the most precise
material- and energy balance:
weighing and data transfer,
energy consumption
Chapter C
·B
igStruc – the StrikoMelter for
structural parts
·E
nergy recovery through preheated
combustion air
·O
xide minimization by near-stoichiometric combustion
·O
xide minimization through self-sealing
lift swing doors
Pr
NE
W
®
C42
BigStruc® – the
StrikoMelter® for
structural parts
Principle
In order to make full use of the potential of lightweight construction in passenger car
body design, an increasing number of structural components are manufactured using the
die-casting process. The use of cast structural components or the trend towards combining individual parts to make integral aluminium components with the aim of reducing the
number of joining and assembly steps required lead to considerably larger flat cast parts
and sprue structures as returns on the one hand and to small-sized thin-walled returns on
the other. Both types of returns pose new challenges for foundries.
The new StrikoMelter BigStruc is suitable for melting large-volume parts as well as
small-sized returns returnswith a very low metal loss and energy consumption. The partly
extremely thin-walled cast parts are preheated in the shaft without direct exposure to
flames and rapidly melted at the foot of the shaft. The metal flows directly from the melting bridge into the holding chamber.
In contrast to a conventional StrikoMelter shaft melting furnace, the StrikoMelter
BigStruc has a special shaft design accepting returns with an area of up to 2.5 m² to be
charged. The height of the shaft can remain unchanged in comparison with the standard
StrikoMelter.
After loading, the shaft is closed with a cover (“hot gas baffle”). Due to the bulky and
large-volume components, there is a larger void volume with a lower bulk density. However, the closed hot gas baffle keeps the heat in the shaft and prevents the energy from
escaping unused. With BigStruc, the preheating and melting of the charging good takes
place in the closed shaft.
In order to load the StrikoMelter at the optimum time in the melting process and keep the
shaft well-filled, the filling level is monitored constantly using a new laser system – even
when the shaft cover is closed. In addition, constant checks are made as to whether the
hot gas baffle is able to close the furnace shaft without problems.
All in all, the proven concepts StrikoMelter Plus+ and StrikoMelter Purefficiency were only
partly modified to meet the new requirements: a modified and enlarged shaft geometry,
a hot gas baffle and the new options of near-stoichiometric combustion and self-sealing
doors. Of course, the BigStruc can also process material and returns of the kind usually
occurring in foundries.
The advantages at a glance:
Shaft melting principle with proven heat recovery for preheating the charge material
Easy loading, including that of large-volume returns with an area of up to 2.5 m²
Reduced energy consumption, even when melting large-volume or thin-walled material,
by making optimum use of the energy in the shaft
Low metal loss regardless of the material used thanks to the minimization of the oxygen
content of the furnace atmosphere by using the options of near-stoichiometric combustion and self-sealing doors
C44
THE PRODUCT
Energy recovery through preheating of the combustion air
OPTIONS
New
Proven
Retrofit
THE ADVANTAGES AT A GLANCE

Energy savings: around 4-5 % at the same

Maintenance-free burners

No NOx emissions

With hot air burners, additional energy
burner power
savings are possible thanks to the higher
flame temperature

Higher energy savings are possible when
In StrikoMelter shaft melting furnaces, the waste heat from the melting process is used to preheat the metal in the shaft. The preheating of the combustion air additionally increases the full utilization of the residual heat of the
exhaust gases for the process. For this purpose, a partial exhaust gas flow is
sucked through a heat exchanger (recuperator), and the resulting heat is used
to preheat the combustion air of the burners to 150 °C. The heated combustion
air is then supplied to the proven standard burners.
The preheating of the air reduces the gas consumption of the combustion
process by 4–5 % at the same burner power. Additional energy savings can be
made with hot air burners as a result of the higher flame temperature compared with cold air burners and the resulting increase in the radiant power of
the gas flames.
The energy savings possible here depend on the melting process. When
operated in an unfavourable mode, for example when the shaft is only partly
filled or during the free-free-melting process, even higher energy savings are
possible.
The system can be used in an economically efficient way at a melting performance of 4 t/h or more.
the shaft is only partly filled or during
free-melting

Low additional space requirements thanks
to compact structure of energy recuperation
including heat exchanger, pressure booster
fan, exhaust gas channels and valves
Heat exchanger for combustion air pre-heating
C45
THE PRODUCT
Oxide minimization by nearstoichiometric combustion
OPTIONS
Oxygen content and excess air in the furnace atmosphere increase the energy
requirements and promote metal oxidization and corundum formation. Our
new development of near-stoichiometric combustion minimizes both. A newly
developed measuring line determines the ideal ratio of air and combustion gas
in order to set the optimum combustion, i.e. combustion with very little excess
air (near-stoichiometric combustion with λ = 1.02). As a result, the oxygen concentration during the melting process, and with it the oxidization of the metal,
is prevented and corundum formation in the furnace is reduced. The burner
is set to near-stoichiometric combustion as part of the commissioning of the
furnace. In addition, an actuator drive with parameterization software allows
the continuously variable adjustment of the burner power.
New
Proven
Retrofit
THE ADVANTAGES AT A GLANCE

Minimum oxygen concentration during the
melting process
· Reduced oxidization of the metal
· Reduced corundum formation

Maximum efficiency of the melting process

Further reduction of the energy consumption as only very little excess air now needs
to be heated up

Burner adjustement in comparison: Burner left side and in the middle correctly adjusted, on
the right side: the flame is too cold, too short
No CO or NOx emissions as a result of the
combustion process
C46
THE PRODUCT
Oxide minimization by self-sealing
lift swing doors
OPTIONS
New
Proven
Retrofit
THE ADVANTAGES AT A GLANCE

Further improvement of tightness
· Lower heat losses in melting area
· Lower heat losses in holding area

A new self-sealing lift swing door is now available for the melting chamber
door and for the door in the holding area of the StrikoMelter. This door is
opened and closed using an electric motor. The new parallelogram guidance
means that it swivels further out from the furnace body to allow the rear side
to be cleaned without removing it.
In addition to the self-sealing lift door already in use in the StrikoMelter PurEfficiency and the StrikoMelter Plus+, a new door concept is now available for
all large StrikoMelter models (i.e. for all models with a lift door). The heavy lift
swing doors have a revolving seal and offer a number of advantages.
Further reduced risk of corundum formation by reliable prevention of the false air
intrusion

Safe lifting of the door seal from the sealing
surface on the furnace thanks to parallelogram guidance
· Increased life timetime of the door seal

Option of cleaning the inside of the door

Replacement of the door seal without remo-

The lift swing door is already in successful
without removing the door
ving the door
permanent operation at several locations
worldwide

The advantages take effect when hot gas
baffles are used
Lift swing door with parallelogram guidance, installed at the melting zone.
All of my
KNOWLEDGE
for your safe
processes
The most resource friendly furnace is only profitable if it works. Always.
C48
THE PRODUCT
StrikoMelter® PurEfficiency®
OPTIONS
New
Proven
Retrofit
THE ADVANTAGES AT A GLANCE

Energy consumption during melting 10–15 %

Lower surface temperatures thanks to new

Optimized flow conditions in the furnace

No hotspots, therefore longer life time of
lower than it is with the StrikoMelter
insulating materials
chamber
the refractory material
The StrikoMelter PurEfficiency is a shaft melting furnace for aluminium foundries which is remarkable for its especially efficient utilization of energy during
the melting of returns and ingotingotsingots. For application in sand casting,
permanent mould casting and high-pressure die-casting, and the word soon
spread among foundries all over the world. As a result 40 systems are now
already in operation worldwide. Also, the energy consumption values even
go considerably below the ones we promised at the GIFA 2011. The energy
consumption of the StrikoMelter PurEfficiency is 10-15 % lower than that of the
StrikoMelter Plus+. Three different sizes are available
The recent product revision allowed the energy balance of the furnace to
improve further. Thus, the melting chamber was optimized for more favourable
flow conditions and the steel construction was designed to achieve maximum
stiffness in a resource-friendly way with optimum utilization of materials.
Further potential for energy savings was utilized by achieving a lower surface
temperature thanks to the use of new insulation materials. The elimination of
hotspots in the furnace geometry has further increased the intervals in which
relining is necessary. Also, a newly developed lining concept reduces the
relining costs.
StrikoMelter PurEfficiency – one of the fourty units installed worldwide
Up to now, 40 StrikoMelter PurEfficiency systems with a total melting performance
of 89,000 kg/h (534,000 t/a) have been taken into operation worldwide. And not
just in the countries specified below, but also in France, Italy, Korea, the Netherlands, Poland and Russia. The list is getting longer all the time. If necessary, we
can gladly organize a reference visit to let you to get to know the PurEfficiency in
real-life foundry operation.
Excerpt from projects realized and consumption values achieved
Furnace type
Country
Delivery date
Performance record
Performance
@ 720°C
MH II-T 3000/1500 G-eg
PurEfficiency
Czech Republic
11.06.2011
543 kWh/t
@ 740 °C
513 kWh/t
MH II-T 4000/2500 G-eg
PurEfficiency
Austria
08.11.2012
568 kWh/t
@ 760 °C
508 kWh/t
MH II-T 6000/3500 G-eg
PurEfficiency
Czech Republic
12.03.2013
536 kWh/t
@ 730 °C
521 kWh/t
MH II-T 4000/2500 G-eg
PurEfficiency
Mexico
22.04.2013
489 kWh/t
@ 720 °C
489 kWh/t
MH II-T 6000/3500 G-eg
PurEfficiency
Turkey
25.10.2013
562 kWh/t
@ 740 °C
532 kWh/t
MH II-T 3000/1500 G-eg
PurEfficiency
Germany
10.07.2013
595 kWh/t
@ 750 °C
550 kWh/t
MH II-T 4000/2500 G-eg
PurEfficiency
Hungary
02.12.2013
529 kWh/t
@ 745 °C
492 kWh/t
MH II-T 3000/1500 G-eg
PurEfficiency
Czech Republic
04.09.2014
598 kWh/t
@ 740 °C
560 kWh/t
MH II-T 4000/2500 G-eg
PurEfficiency
Slovakia
17.02.2015
547 kWh/t
@ 740 °C
517 kWh/t
MH II-T 4000/2500 G-eg
PurEfficiency
Mexico
09.03.2015
522 kWh/t
@ 720 °C
522 kWh/t
C50
THE PRODUCT
Metal preservation with the
StrikoMelter®
OPTIONS
New
Proven
Retrofit
THE ADVANTAGES AT A GLANCE

Metal preservation up to 99.75 %

Low absorption of hydrogen

High quality of the melt
Performance test in a foundry:
Initial data:
Furnace type
Gas consumption
MH II-N 6000/3500
G-eg PurEfficiency
89,904 kWh
163.792 kg
Feed material
– of which 73 %
ingotingots and 27 %
returns
Total duration of
performance test
45.3 h
Results of measurement:
Specific energy
549 kWh/t (incl.
consumption
cleaning process)
Specific melting
performance
3.6 t/h
Dross quantities measured:
Melting chamber
215 kg or 0.13 %
Holding chamber
150 kg or 0.09 %
Against the background of rising cost pressures on the one hand and the
increase of costs for raw materials and energy on the other hand, the question
of the metal yield plays a vital role for aluminium foundries. Other parameters
are crucial too, such as a high melting performance at a low energy consumption, current and future aspects of environmental and occupational safety,
high availability, low maintenance and service costs and a long life time of the
refractoryrefractory lining. The StrikoMelter performs all of these tasks via
the multiple-stage use of the thermal energy of the burners and thanks to its
innovative melting concept. This is based on the subdivision of the furnace
chamber into three separate zones: the preheating zone in connection with the
ETAmax technology specially developed for the StrikoMelter, the melting zone
and the holding bath.
As the raw material aluminium is usually supplied in perfect metallurgical
quality, the main preoccupation in melting operation is to preserve this quality
by preventing contamination. The principal dangers here are humidity, oxidization through the oxygen in the air and the intrusion of solid contaminations
such as dross.
Humidity can potentially impair the metal quality, for example as a result of
storing returns or ingotsingotingots outdoor. The undesirable consequence of
this is an increase in the hydrogen content of the melt, with all of the quality
problems this entails. In the StrikoMelter, adhering water or other humidity
evaporates while still in the preheating zone, so that only perfectly dried material enters the melting zone. In addition, excessive contact of the molten metal
with oxygen in the air is avoided. To minimize oxides further, the burners in the
melting zone are arranged to make direct contact between flames and metal
impossible. As a result, the aluminium only melts at the lowest point in the
melting shaft,and then flows the short distance into the subsequent holding
bath without turbulences. Dross as well as solid contaminations remain in the
melting area and are removed from there.
Practice-related tests performed during commissioning as well as performance
tests have shown that, when ingotingots are used exclusively, a metal loss of
only 0.25 % can be realized (i.e. a metal preservation of 99.75 %). With raw
materials consisting of 50 % ingotingots and 50 % returnsreturns, the metal
loss totalled 0.6 %, i.e. the metal preservation was 99.40 %.
C51
THE PRODUCT
Automated and specific
melting solutions
OPTIONS
StikoWestofen also offers solutions for highly automated foundry-specific
melting demands. Examples realized recently include several systems for a
northern German automotive manufacturer:
The manufacturer in question required a furnace concept which provides a
high degree of automation and maximum metal quality. The furnace is charged
via two roller conveyors, one for the returns and one for the ingots. Four
loading containers can be set per roller conveyor. The mixing ratio of returns
and ingots in the shaft can be varied. This allows extremely flexible operation
while providing a large buffer volume between the individual loading processes of the roller conveyors. In each case, a shaft melting furnace StrikoMelter
MH II-N 6000/3500 PurEfficiency was run for low energy consumption and low
metal loss.
The heart of the concept, which achieves the maximum metal quality, is a
tiltable holding furnace with a bath capacity of 20 tonnes. The transfer launder
between holding furnace and melting furnace is aligned with the tilting axis
and is hermetically sealed off from the surrounding atmosphere using an
innovative sealing concept. In this way, the intrusion of oxygen into the system
is reliably ruled out.
A siphon holds back the dross in the melting furnace, so that only clean melt is
transferred to the holding furnace, where the metal is kept at the tapping temperature selected. As a result of the long residence time in the holding furnace,
contamination-free molten metal forms under a thin protective oxide layer on
the surface of the bath. In the next step, this metal is transferred to the transfer ladle by tilting the furnace. This is where another new development ensures
maximum metal quality: thanks to careful tilting of the transfer ladle, the metal flows in with little turbulence. Upon completion of the filling process, the
transfer ladle is automatically moved back into an upright position and moved
to the impeller station.
New
Proven
Retrofit
THE ADVANTAGES AT A GLANCE

Maximum metal quality of the melt
· Intrusion of oxygen ruled out
· Contamination-free
· Optimized, turbulence-free filling of the
transfer ladle

Extremely flexible operation

Large buffer volume

High degree of automation

Low personnel requirements
C52
THE PRODUCT
Hot gas baffle
OPTIONS
New
Proven
Retrofit
THE ADVANTAGES AT A GLANCE

Free-melting process shortened by around

Energy consumption reduced by around

Up to 4 % increase in productivity and
20 %
15 % during the free-melting process
system efficiency

Higher metal yield

The hot gas baffle is also effective for
increasing the energy recovery with charge
material which has a large void volume
(remelting of large-volume components, for
Another new development from our engineers has now found its way into a
large number of foundries: the hot gas baffle. During daily furnace cleaning,
the melting chamber must be melted free at full burner power until the remaining dross can be removed. In contrast to the standard shaft cover, which could
only be used in holding operation up to now (as a cover for the furnace during
holding), the new high temperature-resistant shaft cover keeps the heat within
the furnace during the free-free-melting process. The resulting exhaust gases
stay in the melting chamber for a longer time and transfer their heat to the
metal, reducing the energy consumption used for free-melting by about 15 %.
The waste heat produced and held by the melting process speeds up the melting behaviour of the raw material. The new hot gas baffle reduces the energy
consumption and shortens free-melting by about 20 minutes per process. This
increases the productivity considerably.
The hot gas baffle was taken into operation for the first time by a large
southern German automotive supplier as a retrofit to a StrikoMelter WHS-T
20.000/4000 G-eg. It had proved its worth after just a short time, and the gain
in productivity and the energy saved justified the investment after an extremely short time. Subsequently, the customer selected the additional option of
the heat-resistant shaft cover when ordering further StrikoMelters. Furnaces
already in service were retrofitted with the hot gas baffle.
example structural cast components)

Little or no necessity for cleaning salts for

Can also be used for the sintering process
daily cleaning
during furnace commissioning
Hot gas baffle, half and fully opened
My
ENERGY
for highest
quality
Our innovations make the processes in light-metal casting safer and more efficient.
C54
Modernization
Energy consumption and metal loss are responsible for up to
95 % of total cost of ownership of a melting furnace. This makes
life-long optimization of the systems and the introduction of
measures for increasing the energy efficiency worthwhile. For
this reason, we work on the improvement of our furnaces constantly - and this applies to new furnaces as well as to retrofits of
systems already installed in the foundries. We also offer training
courses in order to train the operators with regard to optimum
system settings and operating modes.
Automatic shaft cover/
hot gas baffle
Modernizing and increasing the performance of the StrikoMelter:
· Triple bath filling level monitoring
AT A GLANCE
· Automatic shaft cover/hot gas baffle
· Shaft filling level laser
Shortens free-melting process by about 20 %
· Automatic tapping valve
Saves around 15 % of the energy in melting–free operation
· SMS error reporting module
· Refractory relining
· Overhaul and replacement of charging unit
· Replacement of control cabinetcontrol cabinet
· Overhaul of steel construction und burner system
· For a precise material and energy balance sheet: weighing and
Increases the efficiency of the total system
Reduces the use of cleaning salts, thus increasing the life
time of the refractory lining
Closes during weekend and holding operation, thus making further energy savings of up to 5 %
transfer of energy consumption data
Triple bath filling
level monitoring
Shaft filling level laser
AT A GLANCE
AT A GLANCE
Increases operational safety
Optimizes the charging cycles and the filling level in the
melting shaft with the purpose of keeping the shaft optimally filled at all times for optimum heat recovery
Additionally monitors furnace filling level and safeguards
against overfilling
Increases the efficiency of the Etamax in melting
operation by up to 10 %
Automates the charging cycles and increases the
operating safety
C55
Automatic tapping valve
Refractory relining
AT A GLANCE
AT A GLANCE
Automates metal withdrawal
Reduces the consumption of natural gas (m³/t Al)
Improves occupational health and safety
Optimizes the maximum melting performance
Improves operational and process reliability
Optimizes the melting process by state of the art
refractory design
Improves system efficiency and availability
Melting capacity available on lease during refractory
relining (gas-fired crucible furnaces)
SMS fault message module
Overhaul and replacement
of charging devices
AT A GLANCE
AT A GLANCE
Automatic forwarding of operating messages and fault
messages to mobile devices
Optimizes the charging cycles and improves the melting
performance
Improvement of the operating and process reliability
Increases operational safety and system efficiency
C56
Modernization of steel
construction and burner
system and replacement
of the control cabinet
A Czech OEM was able to considerably
reduce energy consumption by retrofitting
the latest shaft filling level lasers to four
StrikoMelter systems built in 1999 and
by installing a new refractory lining. This
allowed him to save a total of € 110,000
AT A GLANCE
Reduces the energy consumption according to the state of
the art
annually on the operation of the furnaces.
The one-off purchase costs of € 40,000
thus paid off within just four months.
Optimizes burner setting (including the new option of
near-stoichiometric combustion) ac-cording to the state
of the art
“The precise filling of the shaft achieved with
Improves the operational reliability and process stability
the help of the integrated laser scanner im-
Product innovations can be implemented in existing
melting systems
proved the heat recovery of the ETAmax sys-
Even with relatively old StrikoMelter models, results can be
achieved which are close to those of the current models
tem in the StrikoMelter to such an extent that
we were able to reduce our gas consumption by about ten percent. Without the laser
scanner, the gas consumption totals 63.3 m3
per tonne of aluminium. The new shaft filling
Weighing and transfer of
energy consumption data
level monitoring immediately reduced the
consumption to 57.1 m3 per tonne.”
(The production manager of an OEM)
AT A GLANCE
Measures and records energy consumption and process
data for the assessment and optimi-zation of current operational status
Optimizes the consumption values during the production
process
All of my
POWER for the
best
result
Huge increase of efficiency is possible by modernization.
58
Energy savings up to 20 % possible
due to the new burner technology in
crucible furnaces by StrikoWestofen
in comparison to furnaces with conventional burner technology.
Chapter D
StrikoWestofen
59
INNOVAT IONS
· G as crucible furnace with
flameless burner
· Stirrer for the rapid melting of
chips or chads (Pb)
en
ov
Pr
w
Ne
NE
W
an
d
fo
rr
et
ro
fit
Crucible furnaces
for aluminium,
magnesium and lead
· Casting of magnesium sheet metal
Chapter D
· P umping, dosing and feeding
(Mg and Pb): quick-connect
coupling for pipes used to
transfer molten metal
D60
THE PRODUCT
Gas crucible furnace with
flameless burner
OPTIONS
New
Retrofit
Proven
THE ADVANTAGES AT A GLANCE

Uniform heating of the crucibles (no

Longer life time of the crucibles

Energy savings of up to 20 % in comparison

Continuously variable at uniform exhaust

Exhaust gas outlet at the bottom of
hotspots)
The flameless burner for heating SiC and steel crucibles allows a homogeneous
heating without hotspots, and this makes a significant contribution to extending the life time of the crucibles. The pre-mixing of gas and air and the resulting
near-stoichiometric combustion allow the burner to realize energy savings of
up to 20 % in comparison with standard crucible furnaces. The low flow speed
results in a longer retention time and thus an improved utilization of energy.
The burner is continuously variable at constant exhaust gas values. The exhaust gas outlet is located at the bottom of the furnace. This makes space for
a continuous working platform and simplifies access for loading and cleaning
purposes.
with standard crucible furnaces
gas values
the furnace
· Continuous working platform possible
· Simplified access for charging and cleaning

Porous burner technology can be used for
the gas heating of crucible furnaces for
magnesium and aluminium

Low flow rates allow an even heating heating of the crucible.
The modular structure and the selective
triggering of the modules allow other
geometrical crucible shapes (for example
angular ones) to be heated gentle (life time)
and energy-efficiently.
Two gas fired crucibles, connected by one working and service platform.
D61
THE PRODUCT
Pumping, dosing and feeding
(Mg and Pb): quick connect coupling for pipes used to transfer
molten metal
OPTIONS
During the feeding and dosing of the melt, attachments (nozzles etc.) and
pipes often have to be disconnected. The new quick-connect pipe coupling for
steel and/or ceramic pipes– allows the exchange of system components in the
hot state (up to 680 °C) without the necessity to disassemble screw connections on flanges. The component can be replaced within just two minutes
during operation and the potential risk is low.
New
Retrofit
Proven
THE ADVANTAGES AT A GLANCE

Rapid replacement of system components
even at high temperatures
(for example 680 °C)

No disassembling of screw connections

No Cooling of the pipes prior to disassembly
on flanges necessary
necessary, only brief production downtime

More safety, less potential risks
D62
THE PRODUCT
Stirrer for the rapid melting of
magnesium chips or chads (Pb)
OPTIONS
New
Retrofit
Proven
THE ADVANTAGES AT A GLANCE

No temperature reductions

Improved heat transition on the wall

Homogeneous temperature of the melt

Less calcium deposits

Small open bath surface, hence low
of the crucible
oxidization

Improved efficiency of the system
This autonomous agitator can be used for mixing chips or chads into crucibles
and furnaces. It generates a local vortex into which the charge material is constantly fed. The current immediately pulls the material under the surface of the
bath, melts it and spreads it through the entire bath. In this way, temperature
reductions are avoided, and the heat transitions on the wall of the crucible or
furnace are also improved by the current. As a result, the temperature of the
melt is homogenous at all times and the calcium deposits are low. Also, there
is little oxidization thanks to the small open bath surface.
D63
THE PRODUCT
Casting of magnesium sheet metal
OPTIONS
For the casting of magnesium sheet metal, we have developed a special dosing system for continuous feeding from a pouring nozzle on a twin roll caster.
Here molten magnesium is fed between two horizontal rollers. The dosing
system feeds the material into a headbox.
The headbox is designed as a rectangular crucible furnace. It has a slit-shaped
outlet, so that the melt leaves the crucible already adapted to the geometry
of the nozzle. The crucible is equipped with several heated, temperature-controlled zones, so that the melt is kept at a constant temperature over the entire
width of the pourer (±3 K).
Crucible and nozzle are matched with regard to temperature and flow, and the
dosing pump controls the level in the headbox extremely precisely down to
±1 mm. The constant level guarantees a uniform flow from the nozzle.
New
Retrofit
Proven
THE ADVANTAGES AT A GLANCE

Crucible and pouring nozzle are matched

Extremely constant melt temperature over

Uniform flow from the furnace directly into

Dosing precision of ±1 mm of the required
with regard to temperature and flow
the entire width of the pourer (±3 °C)
the nozzle geometry
level of the melt
64
Know-How
StrikoWestofen
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„The language our quality speaks
is international. We are in constant contact with our customers
worldwide, so we provide solutions matching the requirements
at all times.“
More
KNOW-HOW
together
The moment we sell a product, cooperation starts – cooperation between us and the customer. This is because we are all pursuing the same goal: to develop energy-saving technologies with a high process reliability, apply them and improve them constantly. This goal can best be achieved via a constant exchange
of experience and know-how. In this sense, our customers are valuable “collaborators” who talk to us
personally and give us details of practical application, thus contributing to the constant optimization
of our products by our engineers. This also puts us in a position to develop solutions for local markets
allowing us to meet the requirements on location.
66
Worldwide
StrikoWestofen
Building on knowledge.
Worldwide.
In 25 countries in Europe, Asia and
America, StrikoWestofen is always close
to the customer in the centres of the
light metal casting industry – either with
branches of our own or via service and
distribution partners.
In our competence centre at the
German locations in Gummersbach/
Bomig, our engineering and development departments have been
working for decades on the consistent improvement of our products
in terms of energy efficiency, metal
yield and durability.
Our spare parts hubs allow us to supply
wearing parts and spare parts within one
day in most countries - with an availability
of over 95 percent.
Efficiency. Powered by knowledge.
www.strikowestofen.com
StrikoWestofen is a globally active manufacturer or thermal process technology for the
light metal casting industry, providing energy-efficient solutions for pressure die-casting,
sand die-casting, low-pressure die-casting
and continuous die-casting.
67
68
Spare Parts & Service
The StrikoWestofen
portfolio
StrikoWestofen offers the complete range of thermal process technology
from one manufacturer. All over the world, we supply energy-efficient solutions matching the requirements of the light metal casting industry.
And because we know that the perfect relationship with our customers does
not end with the delivery and commissioning of a system, we are available to
you with our know-how around the clock – anywhere in the world, whenever
you need us!
Engineered solutions for the
non-ferrous foundry industry
> StrikoMelter, StrikoMelter PurEfficiency,
StrikoMelter Plus+, StrikoMelter BigStruc
· For melting ingots, T-bars, sows and returns of any size,
and for holding of Al-melt
· For melting aluminium chips
> Westomat, Westomat Plus+
· For holding and dosing
· Heated by electricity
> Schnorkle
· Safe metal transfer
· Safe filling of furnace
> Holding furnaces
· With and without crucible
· Heated by electricity or gas
> Low-pressure casting furnaces
· With and without crucible
· Heated by electricity
> Magnesium melting and dosing systems
· For alloying, melting, remelting, dosing and in-cell recycling
· Consultancy and know-how transfer
> Charging systems
> Foundry accessories
· Degassing units
· Preheating systems
· Transfer ladles
· DynaVac density index meter
· Liquid metal transfer (heated launder systems)
> Worldwide presence, service and production
StrikoWestofen
Efficiency. Powered by knowledge.
www.strikowestofen.com
69
For maximum productivity
The StrikoWestofen service range guarantees maximum productivity
for your production. With their competence in the field of systems
development, our technical experts are highly qualified to develop an
individual concept for you that guarantees a maximum of productivity.
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Punctual logistics
Our spare parts hubs in Europe, America and China allow us to deliver within one day in most countries. And we guarantee the lowest
possible costs.
Trained personnel
Our employees know what’s important in their disciplines. Experienced experts from all departments are trained regularly, and in
turn they train the new generation of experts. In internal training
courses, they provide information on innovations in their field of
activity. An intense transfer of know-how guarantees uniform standards at all locations.
Worldwide service
There are 5 inhabited continents on Earth. StrikoWestofen is represented on all of them, either with locations of its own or via our
distribution, service or production partners. We provide our customers worldwide with service that crosses boundaries – and not just
national ones. 24 hours a day and 365 days a year.
Original parts available worldwide
The StrikoWestofen spare parts pledge applies worldwide and
throughout the entire service life of our solutions. All spare parts
required are usually available from stock, and we get them where
they’re needed in the shortest possible time.
Repairs and service
Make use of the know-how of our technical service employees for
maintenance and service work and for repairs. Know-how coming
directly from the manufacturer guarantees the rapid localization and
elimination of errors as well as experienced service work to ensure
especially short downtimes.
24-hour hotline
We are available for our customers 24/7 and 365 days a year. Via
our service hotline +49 2261 7091-129, trained technicians provide
immediate and competent assistance for all types of system.
For further contact addresses, please see our homepage
www.strikowestofen.com
www.strikowestofen.com
StrikoDynarad Corp.
501 E. Roosevelt Ave
MI 49464 Zeeland
USA
Phone: +1 616 7723705
[email protected]
StrikoWestofen GmbH
Hohe Straße 14
51643 Gummersbach
Germany
Phone: +49 2261 7091-0
[email protected]
StrikoWestofen GmbH
Service & Spare Parts
Carl-Zeiss-Straße 12
51674 Wiehl-Bomig
Germany
Phone: +49 2261 7091-129
(24 / 7-Hotline)
[email protected]
StrikoWestofen
Thermal Equipment
(Taicang) Co., Ltd.
N° 18, Suzhou Road
Taicang 215400
Jiangsu Province
China
Phone: +86 512 53359974
[email protected]
SWO Polska Sp. z o.o.
ul. Zakładowa 9 B
47–100 Strzelce Opolskie
Poland
Phone: +48 77 4610446
[email protected]
Striko UK Ltd.
Unit 24 Jupiter Business Park
The Airfield Estate, Hixon
ST18 OPF Staffordshire
Great Britain
Phone: +44 1889 271155
[email protected]
– free of charge –