CHEMISCHE WERKE GMBH

Foundry Industry

in Germany

Dr. Carsten KuhlgatzPresident (CEO) Hüttenes Albertus-GroupBoard Member of German Foundry Association (VDG)Board Member of Technical Section of German Foundry Association

Hüttenes Albertus, Status and

current Developments

September 2014

05.09.2014

Supply Chain

04.09.2012 2

Hüttenes-Albertus

Position

Status Quo

Development

Current Topics

05.09.2014 3

Global Network

Hüttenes-Albertus

Position

Status Quo

Development

Current Topics

05.09.2014 4

Global Surrounding

Postion of German Foundry Industry

Hüttenes-Albertus

Position

Status Quo

Development

Current Topics

05.09.2014 5

Foundry Market: Focus Turkey

0

500

1.000

1.500

2.000

2.500

3.000

3.500

4.000

4.500

Switzer

land

Hungar

yNorw

ayDenm

ark

Belgium

Finlan

dPor

tuga

lAus

tria

Slovenia

Sweden

Czech

Rep

.

United K

ingdom

Poland

Spain

Italy

Turke

yFra

nce

Germ

any

1.000 t

Reference: CAEF, Poland estimated

Picture: Soschinski (BDG)

Europe: Iron and Steal Casting 2012

Postion of German Foundry Industry

Hüttenes-Albertus

Position

Status Quo

Development

Current Topics

05.09.2014 6

0

100

200

300

400

500

600

700

800

900

1.000

Belgium

Denmark

Norway

Finlan

dSwitz

erlan

dPort

ugal

Slowen

iaSwed

enCze

ch R

ep.

Hungar

yGre

at B

ritain

Spain

Austria

Turke

yPola

ndFra

nce

Italy

German

y

1.000 t

Picture: Soschinski (BDG)

Reference: CAEF, Poland estimated

Europe: Non-Ferrous Metal 2012

Postion of German Foundry Industry

Foundry Market: Focus Turkey Hüttenes-Albertus

Position

Status Quo

Development

Current Topics

7

German foundries are well positioned in the global competit ion. They areclosely linked with a powerful industrial cusumer field and with markets withgrowth potential. Reference: ifo Institut, Munich: Casting 2020

Well

positioned

600 companies

78,400 employees

13 billion EUR sales

Hüttenes-Albertus

Position

Status Quo

Development

Current Topics

Postion of German Foundry Industry

05.09.2014

05.09.2014 8

Hüttenes-Albertus

Position

Status Quo

Development

Current Topics

Global Surrounding

Postion of German Foundry Industry

05.09.2014 9

Global Surrounding

Postion of German Foundry Industry

Hüttenes-Albertus

Position

Status Quo

Development

Current Topics

05.09.2014 10

The German Foundry Industry suceeds through:1. Performance

� Quality� Flexibility� Innovation� Know-how� Security of Supply� Productivity� Extension of Supply Chain

2. Further Service Features:� Logistical Support� Assistance in Simultaneous-

Engineering-Projects� Product Development

Germany- Wages↑- Taxes ↑- Duties ↑- Laws ↑

Postion of German Foundry Industry

Global SurroundingHüttenes-Albertus

Position

Status Quo

Development

Current Topics

05.09.2014 11

January 2008 – January 2014

The demand has moved out of the bottom and into a

sideways movement.

Demand of German Foundry Industry

Hüttenes-Albertus

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Development

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05.09.2014 12

Environment

Energy

Productivity

Rapid Prototyping

Salt Cores

Image and recruitmentcampaignes

Hüttenes-Albertus

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Development

Current Topics

Current Topics

05.09.2014 13

Improvement of Environmental Conditions� Focus:

Reduction of Emmissions(Car and Industrial Plants)

� Example: Car

� Solution HA: Coldbox-binder for thin-walled castand for aluminium -gravity die casting

Reduction ofweight

Reduction ofFuel

Consumption

Reducion ofEmmissions

Environment

Hüttenes-Albertus

Position

Status Quo

Development

Current Topics

05.09.2014 14

Downsizing to reduce weight

� Smaler Engine with larger performance (use of turbocharger)

� General Framework:• Reduction of emissions arising during casting processes• Avoiding casting errors resulting of combustion of core binder• High strength and good collapsing of core• Smaler cross sections of the core and longer cores• Different thermal stress in the core package

� Developments of Hüttenes-Albertus

Use of core binding material: from hot and warm curing binders (RCS, Hotbox, Warmbox) to gas curing binders (Coldbox) and inorganic (Cordis)

Environment

Hüttenes-Albertus

Position

Status Quo

Development

Current Topics

05.09.2014 15

Inorganic Binders

Product: Cordis

Emission: Steam

Environment

Hüttenes-Albertus

Position

Status Quo

Development

Current Topics

05.09.2014 16

1.Power plant

• nuclear• coal• gas

2. RenewableEnergies

• waterpower

• solar• wind

power• biogas

� Goal: Reduction of Energy Consumption

- Improvement of energy efficiency- Temperature control of pressure

die casting tools- Reduction of melting amount

� Feeder system

Feeder (CHEMEX)

Rotor hub for wind power systems

� Furan resins and coatings reduced of sulphur

Energy

Hüttenes-Albertus

Position

Status Quo

Development

Current Topics

05.09.2014 17

Process Automation byRobots• coatings• Assembly unit for

construction of corepackages

• Self calibration coatingdevice

Eurokern

MAGMACore shooting simulation

Cooperation between Hüttenes-Albertus and MAGMA

Productivity

Hüttenes-Albertus

Position

Status Quo

Development

Current Topics

05.09.2014 18

• Resin Coated Sands• Layer by layer application of the resin coated sand to a

carrier plate• Outlining by laser beam• Putting the core into the die or the sand form• � Result: Prototype casting• No-Bake• A large form or a core is produced by milling of a sand

casting produced by resin• Assembling of milled parts

Laser Sintering

Hüttenes-Albertus developped an inorganic binder consisting of 2-components, that is used in the core printing process of Voxeljet-Printers =Cordis, RCS, Furan and Nobake

Milling of a core

1

2

3

4

5

• Deposition of powder (1)

• Binder (2)

• Lowering (3)

• Steps (1) to (3) are repeated

• Curing (4)

• Finish (5)

• Aftertreatment / Infiltration

Rapid Prototyping

Hüttenes-Albertus

Position

Status Quo

Development

Current Topics

05.09.2014 19

No Use of salt cores

Production of salt cores with very thincross cuttings and high resistance

Disadvantage: bad decay

Current topic: Flushingof core with water

Salt Cores Used in Die Casting

Aluminium casting with salt core, which can be rinsed with water under high pressure

Salt core produced on die casting machine Ecoline 53

Bilder: Bühler AG, Uzwil Schweiz

Salt Cores

Hüttenes-Albertus

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Development

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05.09.2014 20

Efficiency of German Foundry Industry

well trained staff innovative staff

IMAGE CAMPAIGNES

Image and Recruitment Campaignes

Hüttenes-Albertus

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Development

Current Topics

05.09.2014 21

GIFA + NEWCAST 2015

International trade fair for foundries, foundry auxiliaries and technology June 2015

Düsseldorf, Germany

Hüttenes-Albertus

Position

Status Quo

Development

Current Topics

Thank you very

much for your

attention