A company in detail
> Precision in the details!
GSL – Casting with precision
GSL is one of the most innovative mid-sized steel foundries. The highest
quality and precision are as a matter of course as complete customer
orientation and constant advances. Since 1971, we have been your inno-
vative specialist for the manufacturing of complicated, mould-intensive cast
steel parts from 1 – 1000 kg unit weight. From casting and cost-effective
optimisation all the way up to the manufacture and ready-to-install
machining of the cast parts, we guarantee you the highest quality and fast,
fl exible and reliable delivery.
Our special strength is the development and optimisation of cast products
hand in hand with our customers. Our highest aim is technically optimi-
sed casting solutions with high economic effi ciency for the future oriented
applications of our customers. GSL is unique with its 20 years experience in
the Lost Foam casting process.
Our service spectrum
• The production of complicated cast steel parts with high quality demands
• Consulting in the construction, technical cast design and in matters of
material queries
• Lost Foam production line for steel casting from 1 – 100 kg
• Furan-nobake moulding shop for steel casting from 2 – 1000 kg
• Pattern construction, heat treatment, machining, assembly, inspection
• Prototype production in Lost Foam and furan-nobake
• CAD and simulation techniques
• Quality and economic effi ciency in the product – ideas and competence
in the development – reliability in the partnership with our customers
High quality awareness and constant effort
towards the improvement of products and
processes characterise the employees of GSL.
An example for the fulfi lment of the highest
quality demands are brake discs and
coupler bodies for railed vehicles.
> Modern, environmentally friendly, fl exible!
Lost Foam – Process of the future
GSL is one of the pioneers of this seminal production process worldwide.
Our Lost Foam production lines for steel casting are unique in Europe as
is our meanwhile 20 years experience in this modern and environmentally
friendly casting process.
Lost Foam is a modern, technically and economically effi cient casting process
for the production of cast metallic components with complicated geometry.
The use of vaporisable foam patterns in an undivided mould makes burr free
and dimensionally exact castings possible with excellent surface quality.
The typical “Lost Foam” foam patterns are covered with thin ceramic re-
fractory coating as casting clusters and moulded with a bonding-agent free
mould material. During the casting, the infl owing hot molten steel vaporises
the foam pattern. The hollow space left over is completely fi lled by the mol-
ten steel so that an exact copy of the foam pattern is created.
At the same time, a vacuum placed around the mould material ensures
suffi cient stability of the mould as well as the complete evacuation of the
combustion products created by the foam pattern. The subsequent combusti-
on of the evacuated casting gases leads to a casting process that is almost free
of emissions with low energy demands and closed mould material circulati-
on that is free of bonding agents.
The advantages
• Large degree of freedom in the design of cast parts
• Suitable for thin-walled near-net-shape castings with reduced fettling
and post-processing demands
• High dimensional exactness with low tolerances
• Superior surface quality, elimination of core and partition burrs
• Economically effi cient process from prototype to large series
• Environmentally friendly process: low emissions, low energy consumption
Performance characteristics of Lost Foam steel casting
• Raw casting tolerances – CT7 to CT9 according to EN ISO 8062
• Wall thicknesses – from 3 mm
• Surface quality – Rz 63 to Rz 100
• Cast part dimensions – maximal 700 x 700 x 700 mm
• Pre-cast holes – from Ø 4 mm
• Materials – low alloyed up to high alloyed steel casting from 0.10 % C
All Lost Foam cast parts are created based on foam models. The cementing of
individual model segments together into a casting model enables extremely
complex cast part geometries. As examples of this take a look at the models and
the associated cast steel parts for a grill plate (left), a drill hook (middle) and
a water cooled grate rod (right).
> Precision means: Don’t leave anything to chance!
Sand casting – the fl exible casting process
Sand casting using the nobake process is an especially fl exible casting
process for small and medium sized series. The bonding of the mould
material with an artifi cial resin enables the fl exible adjustment of the casting
mould to the size and geometry of the required cast part. Cast parts with
excellent surface quality and dimensional accuracy are created in this way.
The advantages
• Flexibly applicable for large and small cast parts
• Good dimensional accuracy and high surface quality
• Suitable for multi-part moulded core intensive cast parts
• Economical production of small series using inexpensive pattern
equipment
• Changes are easily made
• Short delivery times are possible
Produced using the
sand casting process:
Crushing ring for roller mills
Produced using the
sand casting process:
The towing bar for the fi eld of
railed vehicle technology.
Produced using the
sand casting process:
Sleeves for the transportation
of abrasive bulk solids
> It’s all in the details!
Steel – the versatile material
Perfect products can only be created through the combination of optimal cast
part construction and choosing the material that is appropriate to the
demands. We possess comprehensive material and processing know-how for
all the materials utilised.
The materials
The versatile material group of steel provides suitable materials for many
application purposes. Steel casting is always used these days if the compo-
nent thereby produced is going to be placed under extreme stresses. This
can mean that high rigidity, corrosion resistance, wear resistance, heat re-
sistance or high temperature strength is required.
With more than 150 active materials for every application case, GSL offers
the most suitable steel casting material including the appropriate heat
treatment. Our experience in various customer sectors and well-
established knowledge of material fundamentals allow us to support you
in the choice of the right material for your component.
In addition to many normed materials from national, European and
international norms, we also produce customer-specifi c own develop-
ments for special applications. The fl exible melting technology with basic
steel types and alloying materials in the induction furnace enables the
production of almost all technically usable steel types at a high quality
level.
An overview of the materials
• Heat resistant – High alloyed chrome and chrome-nickel steels for application temperatures
up to 1,200 °C
• Stainless – High alloyed chrome-nickel steels for corrosion resistant application
• Wear resistant – High alloyed materials for components that are exposed to abrasive or percussive wear
• Non-magnetic – High alloyed chrome-nickel steels or manganese steels for non-magnetic components
• Cryogenic – Alloyed cast steel with increased toughness at cold temperatures
• Quenched and tempered – Alloyed and heat-treated steel casting with specifi cally adjusted mechanical
properties
• High temperature strength – Tempered cast steel for increased application temperatures between
400 – 600° C
• Unalloyed and low alloyed – Steel casting for general applications with good welding and machining
characteristics
High tensile steel
Brake discs for the railed vehicle
engineering sector
Rust free
Console for guidance tracks
in the food industry
Non-magnetic
Anode holder for
aluminium electrolysis
Heat resistant
Grill plate for cement fac-
tories with up to 1,100 °C
application temperature
Wear resistant
Transport screw conveyor for
abrasive bulk solids
High tensile steel
Brake discs for the railed vehicle
engineering sector
Quenched and tempered
Highly stressed component for
railed vehicle clutches
Unalloyed and low alloyed
Components for printing
machines made out of
carbon steel
Cryogenic
Coupler boddy for use at
low temperatures
High temperature strength
Grate support for high
stresses up to 600 °C
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Architecture and construction
Connection nodes made out of
cast steel
> Demands perfectly mastered!
Specialist for individual solutions
Each sector places extremely specifi c demands on cast components and the
material used. Thanks to our 35 years of experience we don’t just know this
but are also able to perfectly implement it.
The sectors and their demands
• Cement industry – We cast complex grate plate geometries for clinker coolers
using the Lost Foam process. For the transport and the grinding of the cement
we utilise our wear resistant materials.
• Waste incineration – For incinerators, we produce a comprehensive palette of
air and water cooled grate bars as well as cast parts for the lining of the oven.
• Industrial furnace construction – Our highly heat resistant materials are used in
annealing and feeding equipment. We can quickly and fl exibly produce small
series and large cast parts using our sand casting process.
• Railed vehicle engineering – We cast coupler and chassis parts as well as brake
discs for component producers for railed vehicle engineering. Comprehensive
inspection possibilities ensure the required quality standard.
• Transport and grinding technology – We offer our customers a variety of wear
resistant materials for the most varied of demands given by transport and grin-
ding technology. When required, we can also deliver the cast parts machined
ready-to-install.
• Architecture and building construction – The distribution of force of adapted
construction components can be cast with an aesthetic appearance using steel
casting. We work fl exibly together with our customers even with tight time
scheduling.
• Mechanical Engineering – We produce individual parts as well as small and
medium series in the various cast steel qualities. If necessary, we machine the
cast parts in our own workshop or in cooperation with reliable partners.
Railed vehicle engineering
Coupler casting
Industrial furnace
construction
Charge carrier
Waste incineration
Water cooled grate bar
Transport and grinding
technology
Switch rotor
GussStahl Lienen
GmbH & Co. KG
Industriestraße 10
D - 49536 Lienen
Tel. +49 54 83 7454 - 0
Fax +49 54 83 7454 - 54
www.gsl-lienen.de