> Precision in the details! · friendly casting process. Lost Foam is a modern, technically and economically effi cient casting process for the production of cast metallic components

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

[email protected]

www.gsl-lienen.de