Geopolymer Foundry

Technology of production of molds and cores in our new foundry is based on self-hardening mixture with a geopolymer-based binder system. Mixtures based on these binders are used in grey cast iron and steel foundries and in construction industry. Due to lower melting and casting (in comparison to grey cast iron and steel foundries) temperatures the process must have been significantly altered in order to ensure such type of sand mixture could be used with aluminium.

This technology is an ecological alternative for widely used toxic, highly flammable and carcinogenic furan compounds, which we as a foundry allocated in a protected area, cannot use.

The technology allows us to produce shapes that are more complex and also allows positioning chills on places and areas where it is very difficult or unrealistic in comparison to the foundry using bentonite mixture. We can also produce larger parts with minimum surface defects such as sand bucles or metal penetration thanks to the fact that no additional water is mixed into the sand mixture.

The complete line is made up of continuous mixers, compaction table, rotary cranes with endless slewing, gantry crane, melting furnaces, vibratory grid and sand reclamation system.

The engineering department designs castings and casting toolings in the 3D program SOLIDWORKS with the support of the modern simulation program MAGMASOFT®, which is used to verify the casting design and casting technology and also predicts possible defects in the casting. We offer cooperation with the customer in the stage of design, streamlining and optimisation of the final solution including the proposal of ideal aluminium alloy - a beneficial service to our customers. When designing the casting equipment, we use computer simulation of the casting process and of the solidification of the molten material. We can also provide a proposal of solution of transition to aluminium alloy from a different material (such as wrought material, iron etc.).

Depending on dimensions, there is possibility to produce parts weighing up to 150 kg. Moulding frames have max. size 1200 x 1200 mm.

The whole production line is made up of six basic units:

1. Core manufacturing.
2. Mould manufacturing.
3. Alloy melting and preparation.
4. Mould jointing and casting.
5. Core- and mould breaking.
6. Sand reclamation.

Finishing operations

1. Trimming and grinding of gatings and risers - newly with grinding machine Koyama
2. Blasting with chrome steel stainless granulate and corundum mixture.
3. Pressurizing of castings up to max. pressure of 6 bar.
4. Heat treatment T4, T6.
5. Assemblies according to customer specifications.
6. In cooperation, we offer the following surface treatment based on customer specifications - protection against corrosion, powdered surface finish, anodizing etc.