The European Foundry Industry · Europe: Non-Ferrous Castings 2010/2013 ( sorted by 2010) Source: CAEF . Production volume 2013 . 3.545 million tons . Compared with . the first year

- 1 - © CAEF, www.caef.eu

International Foundry Forum, 26 - 27 Sept 2014 in Venice - CAEF The European Foundry Association

The European Foundry Industry Structure, Key Figures, Forecasts

and a brief Insight into Trends

IFF 2014 - Venice

CAEF - The European Foundry Association

Vorführender

Präsentationsnotizen

I am going to use various structural data, key figures, a new forecast and some examples of important trends to introduce you to the spectrum of Europe's foundry industry.



Production: 15.2 m tons Fe: 11.6 m tons; NF: 3.6 m tons Value: approx. 41.3 bn € Fe: 22.2 bn €; NF: 19.1 bn € Employees: 284,700 employees Fe: 166,200; NF: 118,500 Foundries: 4,958 foundries Fe: 2,100; NF: 2,858

European Foundry Industry Key Figures 2013

Pict

ure:

BD

G

Source: CAEF

Vorführender


Fe means Iron, Ductile and Steel Castings, NF = all light metals and copper and zinc The European foundry industry produces almost more than 15m t of cast components with a production value of more than 41bn Euros. This output comes from almost 5,000 companies employing a workforce of roundabout 285,000.



India9%

R. of World2%

Japan5%

Taiwan1%

Korea2%

CAEF15%

Brazil3%

Canada1%

Mexico2%

USA13%

China43%

Russia4%

Casting Production Main Regions

Source: CAEF, moderncasting, national associations, Data 2012

Vorführender


On the basis of the data from 2012, therefore, the European foundry industry accounts for 15 % of the global casting production. As my predecessor told us so impressively, it is the second most powerful extended foundry region after China.



0

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China CAEF USA Russia India Japan

m to

ns 2000 2010 2012

European Foundry Industry Fe-Castings – Second Worldwide

+274% -22% +268% +1% -8% -38%

Source: CAEF (2000 incl. Turkey) , moderncasting, national associations

Impact of 2008/2009 followed by slight recovery

Comparison 2012:2000

Vorführender


We see clearly that the European foundries had to deal with a slight decline in casting production in the decade from 2000 to 2012. Ultimately, the causes for the decline in production are rooted in 2008 and 2009. Production slumped so massively that the losses could not possibly be made up in 2010 alone. To be sure, the production data for 2013, which of course are available for Europe, indicate that the last years were exactly what was needed to nearly make up the losses caused by the recession. Even so, Europe's foundries were able to retain their second rank after China.



0,0

1,0

2,0

3,0

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6,0

China CAEF USA Japan India Russia

m to

ns 2000 2010 2012

European Foundry Industry NF-Castings – Second Worldwide

+33% +324% +16% +12% +450% +17%

Impact of 2008/2009 followed by stable recovery

Source: CAEF (2000 incl. Turkey) , moderncasting, national associations

Comparison 2012:2000

Vorführender


On the non-ferrous metal side, the only effect the recession had was that the positive growth rate was somewhat less than in 2000. Thus, foundries were able to stabilise their second position in the global ranking. This, however, indicates certain trends which I shall discuss in greater detail below.



Zinc1,3%

Grey Cast Iron40,1%

Ductile Cast Iron30,1%

Steel Castings6,0%

Copper Castings1,6%

Magnesium0,2%

Aluminium20,6%

European Foundry Industry: Materials

Source: CAEF, Data 2013

Vorführender


Having a closer look at the materials side it is clear and not suprising that Grey cast iron is dominating with a share of 40 %. Ductile cast iron (including Vermiculargraphit) represents 30 % of the European Casting structure. Steel castings acounting for 6%. Jumping to the non-ferrous sector Aluminium is the dominating material with a share of 21 %. Magnesium as the other light weight material represents only 0.2 %. Copper castings are calculated with nearly 2 % and zinc for a little more than 1 %.



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ry

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Finlan

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Belgium

Sloven

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Portug

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Austria

Sweden

United

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m

Czech

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Spain Ita

ly

Turkey

France

German

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2010 2013

1.000 t

Europe: Ferrous Castings 2010/2013 (sorted by 2010)

Source: CAEF

Production volume 2013 12.231 million tons Compared with the first year after the crisis 2013:2010 = + 4.5 %

Vorführender


Needless to say, the European foundry industry comprises many different nations with larger or smaller casting industries. The ferrous castings side clearly shows that, judging by volume, the European market is dominated by six foundry nations. All in all, production was successfully increased during the last years compared to the first year after the crisis by nearly 5 % to 12.2m t. Of course, all supposedly minor foundry nations are home to potent foundries capable of holding their own on the global market, of which quite a few have their own unique selling points.



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Belgium

Denmark

Norway

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Portug

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Sloven

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Sweden

Czech

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Hunga

ry

United

Kingdo

mSpa

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Austria

Turkey

Poland

France Ita

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German

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2010 2013

1.000 t

Europe: Non-Ferrous Castings 2010/2013 (sorted by 2010)

Source: CAEF

Production volume 2013 3.545 million tons Compared with the first year after the crisis 2013:2010 = + 10.5 %

Vorführender


The non-ferrous castings side reflects this situation. Here, we have two and/or five dominant nations who are mainly responsible for the output increase by nearly 11 % during the last years since 2010 to more than 3.5m t in 2013. Once again, however, we must remember that in Europe we have a very heterogeneous foundry landscape populated by generalists, specialists, and hidden champions.



CAEF Number of Ferrous Foundries and Employment

26542414

2243 2208 2135 2127 2104

0

500

1.000

1.500

2.000

2.500

3.000

2005 2008 2009 2010 2011 2012 2013

num

ber o

f fou

ndrie

s

Source: CAEF

Foundries 2013:2010 = - 4.7 % Employees 2013:2010 = - 1.8 %

192200

163900173200 169600 166200

0

50.000

100.000

150.000

200.000

250.000

2005 2008 2009 2010 2011 2012 2013

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Driven by automotive platform strategies and similar components: bigger units to manage high volume series. Plus delayed recovery of investment in equipment

Vorführender


If we analyse foundry and employee numbers in the period from 2005 to 2013, we arrive at the following results: After the recession, the number of foundries on the ferrous side has declined by nearly five % to 2,100 companies since 2010. On the other hand, however, the workforce was only down by less than 2 % to roundabout 166,000. This fact can be explained relatively easily. First, the OEMs' trend towards platform and standard-part strategies is taking effect among automotive suppliers, which account for about 50% of the whole. This leads to larger foundries capable of coping with higher-volume production series. At the same time, foundries with focus on labour-intensive heavy hand-moulded castings want to hold there qualified employees. companies that dropped out of the market were relatively small.



CAEF Number of Non-Ferrous Foundries and Employment

2960 2985

27542853 2896 2880 2858

1.000

1.500

2.000

2.500

3.000

3.500

2005 2008 2009 2010 2011 2012 2013

num

ber o

f fou

ndrie

s

Source: CAEF

Foundries 2013:2010 = + 0.2 %

126200

108800110700

113200

118600

95.000

100.000

105.000

110.000

115.000

120.000

125.000

130.000

2005 2008 2009 2010 2011 2012 2013

num

ber o

f em

ploy

ees

Employees 2013:2010 = + 9.1 %

These figures are underlining the positive development of the non-ferrous sector as a whole driven by the recovery at the automotive market.

Vorführender


On the non-ferrous side the foundry head count of roundabout 2850 was stable since 2010. Workforces grew disproportionately by more than 9 %. Once again, one of the moving forces was probably motor-vehicle engineering; green field installations especially were probably established to serve the OEMs' lightweight construction trends. Additional: Only small companies have left the market.



Productivity in the European Foundry Industry 2013

Source: estimation by CAEF and BDG 2012, * in percent of GPO (raw materials and supplies, without energy)

• Ferrous castings average performance: 70 tons (2010=55 tons) per employee with a range up to 120 tons

• Non-ferrous castings average performance: 30 tons (2010=22 tons) per employee with a range up to 58 tons

• Average Company (as an example): Gross Production Value (GPO) = 198,300 Euro per employee Amount of material (43.4 % of GPO*) used = 86,000 Euro per employee Gross profit = 75,600 Euro per employee

Picture: Lickfett

Vorführender


The traditional standards by which productivity is measured are either per-capita volume output or per-capita sales. Both are admittedly tricky because very often, apples are compared to oranges, i.e. mass-produced automobile castings and individually hand-moulded heavy castings. Still, it pays to calculate tonnages. On the ferrous castings side, the average volume per capita across the European foundry industry is 70 tons, although individual figures range as high as 120 tons. �This clearly shows that differences in the production structures of individual companies, such as that between highly automated casting production and heavy hand-moulded castings made singly, necessarily lead to different results. �On the non-ferrous side, we have an average of 30 tons per employee, with a bandwidth ranging up to 58t. But everyone knows: All these calculations are significant influenced by metal and raw material prices and additional turnover and profit are not the same! GPO Ferrous Castings: 190 100 Euro per employee�GPO Steel Castings: 182 100 Euro per employee GPO Non-ferrous Castings (leightweight): 182 700 Euro per employee�GPO Non-ferrous Castings (heavyweight): 314 100 Euro per employee� Germany: Umsatz or total output (Gesamtleistung) 167 000 Euro, amount of material used (Materialaufwand) 52 000 Euro, Gross profit (Rohertrag) 80 TEUR



Export quota European Foundry Industry 2013

Source: estimation by CAEF

• Export quota total (including deliveries inside Euro area) 36 %

• Export quota Euro area 22 %

• Export quota outside Euro area 14 %

• = castings are produced where castings are needed: >85 % delivered directly within the Euro area! The end use of European castings is all over the world! Picture: Soschinski

Vorführender


In the foundry industry, the average export quota amounts to c. 36 %. Because of the peculiar structure of the greater European region, this includes goods delivered within Europe. Estimates indicate that nearly one quarter of all castings are delivered within the Euro Area, with 14% accounted for by deliveries outside the Euro region. Ultimately, the only conclusion we can draw from this is the often-quoted mantra, 'castings are produced where they are needed'. More than 85 % of all castings made in Europe end up somewhere within the euro zone. However, the end user of European castings is the entire world market.



Economy: Current Status and Forecasts

Picture: Fotolia

Vorführender


Let me now pass on to my next subject, the current status of the European Industry and the forecasts for castings in Europe.



Source: Markit

Euro area Purchasing Manager Index (PMI) Sept 2014

Service

Industry

• A closer look at the sectors in Sept • Positive level yes (>50 points),

but dropping significantly!

Vorführender


PMI is the earliest available information about the real delvelopment in the industry! How can the PMI be interpreted? During the last years we had to learn that passing the 50 point barrier coming from the bottom leads to expanding industrial production.�Coming from the upper part and passing the 50 point line the PMI gives a signal that production is starting to decline. The current status gives the signal that industrial production has moved near to stagnation level. The reason are uncertainties for the background of different crises and the bumpy development of investments inside Europe.



Source: Markit

Euro area GDP vs Purchasing Manager Index (PMI) Sept 2014

PMI complete Index GDP yoy

• Close relation GDP and PMI • PMI is the earliest available information on the current status • PMI is no forecasting tool!

Vorführender


But the PMI is no forecasting tool. It can be the basis to calculate a forecast! How exact the PMI works we can see if we overlapp the charts of PMI and the real GDP development. e.g. The PMI is available for September at the End of September. The GDP data are available two month later, more important for historians as for us. Therefor working with the PMI gives first available information about reality!



EURO Area Gross Domestic Product Quarter over Quarter Change in % qoq

Source: Eurostat, forecast 3Q 14 – 4Q 15 Dekabank

Vorführender


What is the message of the PMI? The Eurozone recovery remains weak and economic performance stagnated in the second quarter 2014. We can expect only small growth in the third quarter but it is positive growth! The IMF forecast (International Monetary Fund) is based on a small growth rate in 2014 of 1.1 % followed by a slight recovery of 1.5 % for the next year. This is the picture for the European economy as a whole. Let us now have a first view over the years to come for the foundry industry.



Forecast of Foundry Production until 2018 by IKB Bank

Vorführender


IKB is one of the leading banks in Europe with industrial focus, The bank is close connected to the foundry industry. The experts are working with different calculation models for the customer industries and the foundry industry. Two weeks ago they have finished the first forecast for the years 2015-2018.



• Growing need for castings on a global level

• Based on the development of the vehicle industry, passenger cars as well as truck industry! Driving forces are - the growing wealth in the emerging markets (passenger cars) - and the tight regulations for the truck industry to improve emmission standards and energy efficency

• Impulses for general engineering will come from - chemical industry - food industry and - energy sector

• Building industry will be shaped by - booming infrastructure investments in the emerging markets - and a slight recovery in Europe as well as - positive development in the USA

Source: IKB

Forecast until 2018: Background

Vorführender


IKB forecasts a growing need for castings on a global level for the next years This forecast is based on the development of the vehicle industry, means passenger cars as well as truck industry! �Driving forces are �- the growing wealth in the emerging markets ( impulses for passenger cars)�- and the tight regulations for the truck industry to improve emmission standards and energy efficency Impulses for general engineering will come from - chemical industry - food industry and - energy sector Building industry will be shaped by - booming infrastructure investments in the emerging markets - and a slight recovery in Europe as well as - positive development in the USA



•Global Iron and Steel Casting Production in Mill. Tons (rounded data)

Westeuropa China

Rest-Asien

NAFTA

Südamerika

Afrika

• Western Europe can hold the level with slight increases • NAFTA will profit from the reindustrialisation trend in the USA,

positive development is expected especially for Mexico • The market share of China will grow and India has a chance to catch up

Osteuropa

9 8,9 9,2 9,6

8 7,9 7,9 8,4 12 12 12 13

3 3 3 3 0,3 0,3 0,3 0,4

37 38 40 43

16 16 16 16

Forecast until 2018: Iron and Steel Castings

Source: moderncastings, CAEF, Forecast IKB

Western Europe

Eastern Europe

South America

NAFTA

Africa

India, Japan and Rest of Asia

China

2018 2015 2013 2012

Vorführender


Let us summarize the main points of the forecast for Iron- and Steel Castings Western Europe can hold the level with slight increases NAFTA will profit from the reindustrialisation trend in the USA, �positive development is expected especially for Mexico The market share of China will grow and India has a chance to catch up



Westeuropa

China

Rest-Asien

NAFTA

Südamerika

Afrika

Osteuropa

2,3 2,3 2,4 2,6

1,5 1,6 1,6 1,8 2,6 2,7 2,8 3,0

0,2 0,2 0,3 0,3

0,0 0,0 0,0 0,0

4,5 4,7 5,0 5,0

2018 2015 2013 2012 3,2 3,2 3,3 3,4

• Western Europe will expand the production while the increase in Eastern Europe will be more dynamic

• The positive growth rates expected for the NAFTA region are mainly based on investments of European OEMs

• China will set the pace in Asia Source: moderncastings, CAEF, Forecast IKB

•Global Aluminium Casting Production in Mill. Tons (rounded data)

Forecast until 2018: Aluminium Castings

Western Europe

Eastern Europe

South America

NAFTA

Africa

India, Japan and Rest of Asia

China

Vorführender


For leightmetal castings the message is Western Europe will expand the production �while the increase in Eastern Europe will be more dynamic The positive growth rates expected for the NAFTA region �are mainly based on investments of European OEMs China will set the pace in Asia



A Brief Insight into Trends in the European Foundry Industry beside the Competition of Materials and Casting Processes

• Substitution

• Additive Manufacturing

• Smart Production = Smart Castings

Source: BDG/Soschinski

Vorführender


Now let us jump to the final part of my presentation, the brief insight into trends, Trends beside the competition of Materials and Casting Processes I will concentrate only on three examples: substitution, additive manufacturing and smart production



• After Material: Aluminium DG Weight: 4.2kg

• Advantage Weight reduction of >14kg!

• Before Material: sheet steel

Source: GF Automotive

Current Trend: Substitution e.g. complexe structural parts, door frame passenger cars

Vorführender


The first example is the well running trend to substitute parts e.g. components produced by sheet steel with complexe casted structural parts. In this case a weight reduction of 85 %! There is nothing more to say about that. An perfect example of the performance of the foundry industry, for the important contribution to reduce vehicle weight by castings



Source: Heinz Nixdorf Institute, Fotolia

Current/Future Trend: Additive Manufacturing

• Not only pattern and mould manufacturing

• In future: finished products on metal base

• Rethinking of construction restrictions to use the potential of additive manufacturing

• No „Killerapplication“ or final „Game Changer“ but an additional business for foundries!

Vorführender


The second example is a trend running today with new impulses for the future The idea of additive manufacturing was born some decades ago. No we recognise that there is more than pattern and core making. We have to rethink all learned construction regulations to use the potential of this process. In future we can add the production of finished products made by additive manufacturing. This is for shure no game changer for heavy weight hand moulded castings, But we have the chance to integrate this new production process as a further business opportunity. We can be shure if we don´t do it other industries will make the money!



Source: DMRC

Current/Future Trend: Additive Manufacturing in Metal

• Not only pattern and mould manufacturing

• In future finished products on metal base

• Rethinking of construction restrictions to use the potential of additive manufacturing

• No „Killerapplication“ or final „Game Changer“ but an additional business for foundries!

• Development of new applications using new design rules

• E.g. internal structures

Vorführender


The second example is a trend running today with new impulses for the future The idea of additive manufacturing was born some decades ago. No we recognise that there is more than pattern and core making. We have to rethink all learned construction regulations to use the potential of this process. In future we can add the production of finished products made by additive manufacturing. This is for shure no game changer for heavy weight hand moulded castings, But we have the chance to integrate this new production process as a further business opportunity. We can be shure if we don´t do it other industries will make the money!



• Black Magic vs Smart Foundry

• Equipment interactive connected

• Data mining

• Improvment and stabilisation of all processes

• Leads to maximized efficiency Energy and Material Flexibility, Speed etc.

• That´s all?

Future Trend: Smart Foundry Smart Production needs Smart Castings

Vorführender


Let me finish with a future trend, the smart factory, the circle closes, starting with the key note yesterday Smart Production is based on communication between produced components and production equipment The question is how can a casting be integrated in the communication network of Smart Production? One answer: Integration of RFID Transponder during (!) the casting process! (pressure die casting) Now the casting can communicate with the equipemt around! Positive: The casting can be identified, perfect for tracking and tracing and the casting is secured to be copied! This is one key to open the door to smart production for a casted product, a smart casting Gießtechnisch integrierte RFID-Transponder Fraunhofer-Institut für Fertigungstechnik und Angewandte Materialforschung IFAM Funktionsintegration - CASTtronics® RFID-Bauteilkennzeichnung Zustandsüberwachung mit eingegossenen Sensoren Gießtechnisches Gehäuse für Elektronikelemente RFID – kontaktlose und robuste Bauteilidentifizierung Beispiele für RFID-Transponder�© Fraunhofer IFAMGießtechnisch integrierte RFID-Transponder (RFID: Radio Frequency Identification) bieten die Möglichkeit, das Gussteil anhand einer weltweit einmaligen Seriennummer eindeutig zu kennzeichnen und per Funk zu identifizieren. Im Gegensatz zu konventionellen Technologien zur Bauteilkennzeichnung – wie z. B. dem Barcode oder DataMatrixCode – ist kein Sichtkontakt erforderlich. Vorteile der RFID-Technologie Gegenüber herkömmlichen Identifikationsverfahren (z. B. Barcode oder DataMatrixCode) weist die RFID-Technologie deutliche Vorteile auf: Kabellose Daten- und Energieübertragung Kein Sichtkontakt erforderlich Gleichzeitiges Erfassen mehrerer Transponder möglich (z. B. in Gitterboxen, etc.) Resistent gegenüber rauen Industrieumgebungen (Schmutz, Öl, mechanische Beschädigung, etc.) Verschlüsselung der Informationen möglich Besonderheiten der RFID-Technologie Druckgussbauteil mit eingegossenem RFID-Transponder zur Bauteilkennzeichnung und zum Plagiatschutz�© Fraunhofer IFAMMit der CASTTRONICS ®-Technologie wird der RFID-Transponder direkt in die Bauteilstruktur eingegossen und ist somit vor Beschädigung, Verlust oder Manipulation geschützt im Bauteil integriert. Im Gegensatz zu visuellen Kennzeichnungsmethoden sind Bauteile mit integriertem RFID-Transponder auch nach einer Oberflächenbehandlung (z. B. durch Beschichtung, Strahlung oder Verschmutzung) noch eindeutig identifizierbar. Die Bauteilkennzeichnung ist vor mechanischer Beschädigung oder Zerstörung geschützt. Eine Manipulation durch Entfernen oder Austausch des Transponders ist nicht möglich. Somit bietet die integrierte RFID-Technologie neben der reinen Bauteilerkennung einen innovativen Ansatz als elektronisches Echtheitssiegel gegen Produktpiraterie. Neben dem reinen Auslesen der auf dem Chip gespeicherten Daten können bei Bedarf zusätzliche Informationen hinzugefügt werden, z. B. Produktionsdaten oder Produktinformationen. Weiterhin ist die Verschlüsselung sensibler Daten möglich. Durch die gießtechnische Integration der Funktionselemente entfallen zusätzliche Bearbeitungs- sowie Fügeprozesse und bieten Potenzial zur Kostenreduzierung in der Fertigung RFID-integrierter Gussteile. Anwendungspotenzial für Gussteile Automatisierte Lesestation an einer Förderstrecke�© Fraunhofer IFAMBauteil-Kennzeichnung Das Gussteil erhält über den RFID-Tag eine weltweit einmalige Seriennummer, die aufgrund der gießtechnischen Integration untrennbar mit dem Bauteil verknüpft ist. Plagiatschutz Mit dem eingegossenen RFID-Transponder erhält das Gussteil ein elektronisches Echtheitssiegel, das zum Schutz des Bauteils vor Produktpiraterie oder Verwechslung genutzt werden kann. Produktionsdaten und –logistik Neben der reinen Seriennummer sind weitere Daten direkt auf dem Bauteil ablegbar, z. B. Fertigungsparameter, Produktinformationen oder Kunden- und Lieferdaten. Gespeicherte Informationen aus dem Produktlebenszyklus können zur Prozessoptimierung und Qualitätskontrolle herangezogen werden. In den Prozessen der Fertigung, Bearbeitung oder Montage dient RFID zur Verfolgung und automatisierten Steuerung der Gussteile (Tracking). Ebenfalls sind entsprechende Parameter aus der Produktion und Logistik direkt auf dem Gussteil speicherbar, wodurch eine eindeutige Rückverfolgung im Schadensfall ermöglicht wird (Traceability). Weiteres Anwendungspotenzial Auf dem Datenspeicher können bauteilspezifische Daten abgelegt werden, z. B. Arbeitsanweisungen, oder Montage- und Bedienungsanleitungen. Weiterhin ist die RFID-Technologie einsetzbar zur kabellosen Energieübertragung, um energieautarke Sensorsysteme zu realisieren. Anwendungsbeispiele VIDEO Technologie-Demonstrator mit RFID-Gussbauteilen: »autofaktur - Fabrik der selbststeuernden Produkte« (0:28 - 4,9 MB) VIDEO Eingießen von RFID-Transpondern im Druckguss (2:34 - 8,3 MB) Unser Angebot Die Gießereitechnologie und Komponentenentwicklung am Fraunhofer IFAM unterstützt Sie in der gesamten Prozesskette zur CASTTRONICS ®- Technologie : Ideenfindung und Projektberatung Auswahl der RFID-Transponder Auslegung von Isolationsmaterial und -geometrie Konzeptentwicklung zur Positionierung im Gießwerkzeug Simulation des Gießprozesses Versuche/Testgießreihen Röntgendurchleuchtung und Computertomographie



• Smart Production is based on communication between produced components and production equipment

• The question: How can a casting be integrated in the communication network of Smart Production?

• One answer: Full (!) Integration of RFID Transponder during (!) the casting process! (pressure die casting)

• Positive: The casting can be identified, perfect for tracking and tracing and the casting is secured to be copied (product piracy)!

Future Trend: Smart Foundry Smart Production needs Smart Castings

Picture: EAA, IFAM, Casttronics

Vorführender


Let me finish with a future trend, the smart factory, the circle closes, starting with the key note yesterday Smart Production is based on communication between produced components and production equipment The question is how can a casting be integrated in the communication network of Smart Production? One answer: Integration of RFID Transponder during (!) the casting process! (pressure die casting) Now the casting can communicate with the equipemt around! Positive: The casting can be identified, perfect for tracking and tracing and the casting is secured to be copied! This is one key to open the door to smart production for a casted product, a smart casting Gießtechnisch integrierte RFID-Transponder Fraunhofer-Institut für Fertigungstechnik und Angewandte Materialforschung IFAM Funktionsintegration - CASTtronics® RFID-Bauteilkennzeichnung Zustandsüberwachung mit eingegossenen Sensoren Gießtechnisches Gehäuse für Elektronikelemente RFID – kontaktlose und robuste Bauteilidentifizierung Beispiele für RFID-Transponder�© Fraunhofer IFAMGießtechnisch integrierte RFID-Transponder (RFID: Radio Frequency Identification) bieten die Möglichkeit, das Gussteil anhand einer weltweit einmaligen Seriennummer eindeutig zu kennzeichnen und per Funk zu identifizieren. Im Gegensatz zu konventionellen Technologien zur Bauteilkennzeichnung – wie z. B. dem Barcode oder DataMatrixCode – ist kein Sichtkontakt erforderlich. Vorteile der RFID-Technologie Gegenüber herkömmlichen Identifikationsverfahren (z. B. Barcode oder DataMatrixCode) weist die RFID-Technologie deutliche Vorteile auf: Kabellose Daten- und Energieübertragung Kein Sichtkontakt erforderlich Gleichzeitiges Erfassen mehrerer Transponder möglich (z. B. in Gitterboxen, etc.) Resistent gegenüber rauen Industrieumgebungen (Schmutz, Öl, mechanische Beschädigung, etc.) Verschlüsselung der Informationen möglich Besonderheiten der RFID-Technologie Druckgussbauteil mit eingegossenem RFID-Transponder zur Bauteilkennzeichnung und zum Plagiatschutz�© Fraunhofer IFAMMit der CASTTRONICS ®-Technologie wird der RFID-Transponder direkt in die Bauteilstruktur eingegossen und ist somit vor Beschädigung, Verlust oder Manipulation geschützt im Bauteil integriert. Im Gegensatz zu visuellen Kennzeichnungsmethoden sind Bauteile mit integriertem RFID-Transponder auch nach einer Oberflächenbehandlung (z. B. durch Beschichtung, Strahlung oder Verschmutzung) noch eindeutig identifizierbar. Die Bauteilkennzeichnung ist vor mechanischer Beschädigung oder Zerstörung geschützt. Eine Manipulation durch Entfernen oder Austausch des Transponders ist nicht möglich. Somit bietet die integrierte RFID-Technologie neben der reinen Bauteilerkennung einen innovativen Ansatz als elektronisches Echtheitssiegel gegen Produktpiraterie. Neben dem reinen Auslesen der auf dem Chip gespeicherten Daten können bei Bedarf zusätzliche Informationen hinzugefügt werden, z. B. Produktionsdaten oder Produktinformationen. Weiterhin ist die Verschlüsselung sensibler Daten möglich. Durch die gießtechnische Integration der Funktionselemente entfallen zusätzliche Bearbeitungs- sowie Fügeprozesse und bieten Potenzial zur Kostenreduzierung in der Fertigung RFID-integrierter Gussteile. Anwendungspotenzial für Gussteile Automatisierte Lesestation an einer Förderstrecke�© Fraunhofer IFAMBauteil-Kennzeichnung Das Gussteil erhält über den RFID-Tag eine weltweit einmalige Seriennummer, die aufgrund der gießtechnischen Integration untrennbar mit dem Bauteil verknüpft ist. Plagiatschutz Mit dem eingegossenen RFID-Transponder erhält das Gussteil ein elektronisches Echtheitssiegel, das zum Schutz des Bauteils vor Produktpiraterie oder Verwechslung genutzt werden kann. Produktionsdaten und –logistik Neben der reinen Seriennummer sind weitere Daten direkt auf dem Bauteil ablegbar, z. B. Fertigungsparameter, Produktinformationen oder Kunden- und Lieferdaten. Gespeicherte Informationen aus dem Produktlebenszyklus können zur Prozessoptimierung und Qualitätskontrolle herangezogen werden. In den Prozessen der Fertigung, Bearbeitung oder Montage dient RFID zur Verfolgung und automatisierten Steuerung der Gussteile (Tracking). Ebenfalls sind entsprechende Parameter aus der Produktion und Logistik direkt auf dem Gussteil speicherbar, wodurch eine eindeutige Rückverfolgung im Schadensfall ermöglicht wird (Traceability). Weiteres Anwendungspotenzial Auf dem Datenspeicher können bauteilspezifische Daten abgelegt werden, z. B. Arbeitsanweisungen, oder Montage- und Bedienungsanleitungen. Weiterhin ist die RFID-Technologie einsetzbar zur kabellosen Energieübertragung, um energieautarke Sensorsysteme zu realisieren. Anwendungsbeispiele VIDEO Technologie-Demonstrator mit RFID-Gussbauteilen: »autofaktur - Fabrik der selbststeuernden Produkte« (0:28 - 4,9 MB) VIDEO Eingießen von RFID-Transpondern im Druckguss (2:34 - 8,3 MB) Unser Angebot Die Gießereitechnologie und Komponentenentwicklung am Fraunhofer IFAM unterstützt Sie in der gesamten Prozesskette zur CASTTRONICS ®- Technologie : Ideenfindung und Projektberatung Auswahl der RFID-Transponder Auslegung von Isolationsmaterial und -geometrie Konzeptentwicklung zur Positionierung im Gießwerkzeug Simulation des Gießprozesses Versuche/Testgießreihen Röntgendurchleuchtung und Computertomographie



Heiko Lickfett

CAEF The European Foundry Association +49(0)211/6871-214

[email protected]

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The European Foundry Industry – Yearbook 2013

Vorführender


For more detailed analyses, I recommend ordering the European foundry industry's yearbook for 2011, where end uses are discussed for every material separately.

Documents

The European Foundry Industry · Europe: Non-Ferrous Castings 2010/2013 ( sorted by 2010) Source: CAEF . Production volume 2013 . 3.545 million tons . Compared with . the first year