GTP Schäfer has solved an ongoing problem that has affected many foundries over the years. Frequently fluctuating quality of commercially available synthetic moulding sands and the associated negative effects on casting quality has been resolved with the synthetic moulding sand developed by the Grevenbroich-based company, and marketed under the name CERATEC. CERATEC is characterised by having grains exhibiting an almost perfect spherical shape ensuring optimum compaction of moulds and cores, low binder consumption and high gas permeability. This ensures optimal production of castings having a significantly improved quality. In addition, GTP Schäfer has expanded its portfolio of special moulding materials with the addition of the innovative products CERAPEARL / CERAPEARL 3D and CERASHELL.
Complete control over the entire supply chain ensures consistent product quality
A key factor in the development of CERATEC was that the riser manufacturer was one of the few moulding material suppliers to succeed in controlling the entire supply chain – from the mine to the customer. This was the decisive prerequisite for being able to produce synthetic moulding sand with a consistent quality for foundries.
Fluctuating material quality can cause problems
A fluctuating quality of synthetic moulding sand can cause problems for foundries, as it is associated with higher binder consumption, penetration, mineralisation and casting surfaces exhibiting an inherently higher surface roughness. By using the CERATEC moulding material mineralisation in cored areas that are subjected to a high thermal loading or stress can be eliminated. The required surface quality is almost always achieved without having to resort to a high degree of finishing.
Molding sand CERATEC has firmly established itself in the foundry industry
Increasing practical experience in industrial use with our moulding sand CERATEC shows:
- The time required for fettling is often reduced by more than one order of magnitude (factor 10) or even eliminated completely.
- In certain cases, by switching to CERATEC as the core sand, the cleaning costs are able to be reduced by more than 50 %
- The high Al2O3 content and the purity of the moulding sand result in a significant reduction in emissions, which in turn contributes to high mechanical and thermal stability.
- To achieve the desired level of strength, binder additions can be reduced up to 70% compared to conventional moulding sand.
These advantages ensure that the utilisation of CERATEC in the moulding and core making process offers a significant economic benefit to the founder. CERATEC has become firmly established in the foundry industry.
GTP Schäfer expands its range of special moulding materials
Based on the success of CERATEC and the ever increasing demands on moulding materials and casting quality GTP Schäfer has expanded its product portfolio in the field of specialist moulding materials with the addition of CERAPEARL / CERAPEARL 3D and CERASHELL.
New: CERAPEARL / CERAPEARL 3 D
About CERAPEARL
CERAPEARL is a synthetic sintered moulding material. It has the same positive properties as CERATEC while offering additional advantages: The lower density reduces production costs without negatively affecting casting quality. The processing time of CERAPEARL’s cold box sand mix is significantly longer compared to CERATEC. As a result, it is possible to produce cores from a mixture over a longer period of time without it losing requisite properties increasing productivity – especially when producing filigree cores.
About CERAPEARL 3D
During the development of CERAPEARL 3D, GTP Schäfer focused on one goal: The positive properties of synthetic moulding materials should also be made usable for 3D printed cores and moulds. The innovative company has achieved this goal. With CERAPEARL 3D it is now possible to produce cores and moulds utilising 3D printing techniques without modifying the printer.
New: CERASHELL
To round off the range of special moulding materials, GTP Schäfer has developed CERASHELL ready to use, resin coated sand. CERASHELL combines the advantages of a synthetic moulding material with those of hot box or shell sand ensuring CERASHELL is suitable for the most demanding applications, such as cylinder heads, water jacket and hydraulic casting.
GTP Schäfer will be presenting the new products and much more from 12 – 16 June at GIFA 2023 in Düsseldorf, hall 12, booth E 29 & E 30.
Invitation for GIFA 2023
