In addition to our strategic energy policies, our goal-oriented use of Computer-Based Simulation of the casting process plays an important role in environmental conservation. In the past, process development and prototype testing required the sequential production of (usually multiple) “throwaway” castings in a wasteful trial-and-error process. These prototype castings were then simply discarded after mistakes and/or optimization potential had been identified. Today, these iterative intermediate stages are simulated using advanced computer software. Only after the simulations show satisfactory results does production begin: leftover raw material is melted, a mould is produced, and a real casting is created.
Our process monitoring and quality control measures offer another way to foster the cause of environmental protection. All of our procedures are designed to minimize possible waste production and scrap. Measures to identify possible causes of waste and to minimize the use of resources start with monitoring the sand used in the moulds for optimum mould strength and sand cohesion, to avoid producing unusable moulds and generating waste before casting even begins. They also include ensuring the proper composition of alloys, maintaining the correct casting temperatures and minimum cooling time in the moulds, and monitoring each series as it is produced with an eye to previously determined number of mouldings, to ensure that parts possess the correct dimensions and to avoid producing unacceptable castings.